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Chandra Sekaran
Ansys Employee

What is the exact error message? Typically when there is not enough memory it is due to the size of the mesh but even then the solver will run out-of-core. Is this what you are seeing in the solve.out file (Solution information)? 

If mesh size is the issue then reducing # of substeps won't help. You mention that without transient thermal the model runs. The transient thermal is a separate analysis, right? And you are specifying the times at which the temperature load from transient thermal should be applied to the structural, correct? If this is the case, the model should behave the same way with or without the thermal load.  Can you compare the solve.out from the 2 runs (one that runs and one that fails) to see what differences you see.