A fully GPU-based workflow for building physics emulators of hypersonic flows
Authors: Fabian Paischer, Dylan Rubini, Deniz A. Bezgin, Aaron B. Buhendwa, David Hauser, Florian Sestak, Johannes Brandstetter, Sebastian Kaltenbach, +1 more
Abstract
The ability to resolve complex physical phenomena with high fidelity and at low computational cost is central to addressing key challenges in modern engineering. A prime example lies in hypersonic flows, where the precise prediction of the full flowfield topology, in particular with respect to shock wave location and intensity, is critical. Yet supersonic and hypersonic flows continue to be a stumbling block for traditional reduced-order models and neural emulators that struggle to capture steep gradients in flow states with physical consistency in applications of industrial relevance. To that end, we introduce a fully GPU based workflow that integrates accelerated data generation with the training of neural emulators augmented by uncertainty quantification and physics-aware refinement. Our workflow is enabled by a differentiable high-fidelity solver (JAX-Fluids) which we employ for rapid dataset creation and residual-based improvement of the neural emulator to enhance physical consistency. Building on this framework, we first present a suite of model architectures and analyze their scaling behavior to expose their strengths and shortcomings. We then show that residual-based refinement enables training on cases where only mesh and input parameters are available, substantially reducing residuals and improving physical consistency. Together, differentiable simulation and residual-based refinement yield physics emulators that remain reliable beyond their training distribution, a key requirement for deploying surrogates in real-world engineering design loops.
Hyperbolic conservation laws govern a wide range of transport-driven dynamics featuring shocks, contact discontinuities, and complex wave interactions, posing distinct challenges for deep-learning-based surrogate modeling. While classical numerical methods provide robust and physically admissible solutions, their computational cost restricts applicability in many-query tasks such as parametric studies and design optimization. Conversely, existing neural surrogates offer rapid inference but often fail to respect intrinsic PDE structures, leading to non-physical artifacts, rollout instability, and poor generalization. We present an interpretable, structure-preserving graph neural solver that bridges classical numerical principles with graph neural networks (GNNs). The network is designed as a learned reconstruction-and-flux operator rather than a black-box state updater, thereby inherently preserving key properties such as local conservation and upwinding. Inspired by Arbitrary high-order DERivatives schemes, we further recast message-passing GNNs as high-order space-time predictors, enabling conservative and stable neural updates with large time steps. Evaluation is performed on challenging supersonic flow benchmarks spanning broad parametric variations in geometry, initial/boundary conditions, and flow regimes. The neural solver achieves superior long-horizon rollout stability and accuracy compared with strong surrogate baselines, outperforms low-order discretizations, and delivers orders-of-magnitude runtime speedups over high-resolution simulations.
Generative models have emerged as a powerful paradigm for solving physics systems and modeling complex spatiotemporal dynamics. However, achieving high physical accuracy without incurring high computational cost remains a fundamental challenge, as existing approaches face a critical speed-fidelity trade-off. In this work, we introduce Recursive Flow Matching (RecFM), a generative framework for forecasting complex spatiotemporal dynamics. RecFM enforces self-consistency to align trajectories across discretization scales, reducing discretization errors and improving performance across metrics for physics-based tasks. To our knowledge, this is the first method to achieve high-fidelity one- and few-step (2-4 step) dynamic generation for scientific systems with performance comparable to state-of-the-art multi-step solvers. Across challenging scientific benchmarks, RecFM achieves up to a 20× speedup over leading diffusion-based emulators while improving predictive accuracy. Furthermore, RecFM reduces mean squared error by over 15% compared to vanilla flow matching, offering a scalable and efficient solution for real-time scientific emulation.
Deep generative models and neural operators have demonstrated significant potential for 3D aerodynamic inference. However, they often face inherent challenges in maintaining physical consistency and preserving high-frequency features, primarily due to spectral bias and gradient conflicts within the governing equations. To address these issues, we propose GeoFunFlow-3D, a physics-guided generative flow matching framework. Temporally, we utilize optimal transport theory to build the generation path, ensuring stable training dynamics. Spectrally, we introduce a high-order discrete engine without automatic differentiation (No-AD) to reduce gradient stiffness. Spatially, a topology-aware super-resolution module (SATO) is employed to rigorously enforce physical laws in localized regions such as shock waves. We evaluated our framework on complex industrial datasets. On the BlendedNet dataset, the model successfully avoids mode collapse even under sparse data conditions. For the NASA Rotor37 test, it accurately captures 3D detached shock structures. Compared to conventional operators, GeoFunFlow-3D significantly improves accuracy, reducing the pressure field error (RRMSE) to 0.0215 while maintaining competitive inference efficiency. Ultimately, this work provides a reliable, geometry-driven approach for generating high-dimensional fluid fields.