Learning Interface Breakup: A Geometry-Conditioned Latent Surrogate for Spray Formation
Authors: Julius H Ramlau, Friedrich Hastedt, Tolga Birdal, Ehecatl-Antonio del Río Chanona, Nausheen S Basha, Omar K Matar
Abstract
Designing spray nozzles requires predicting how geometry shapes transient two-phase breakup, but high-fidelity volume-of-fluid (VOF) simulations with adaptive mesh refinement (AMR) are too expensive for iterative design exploration. Standard surrogate models are also challenged by this setting because both the liquid--gas interface and the underlying adaptive discretization evolve across time and geometries. We introduce a geometry-conditioned latent surrogate trained on 797 two-phase nozzle simulations that addresses this by encoding the AMR cell-density field, rather than the full multi-channel flow state, as a compact proxy for where the solver concentrates resolution. From this representation, the model reconstructs transient density evolution and nozzle geometry, and a lightweight second stage recovers the remaining flow variables. On held-out simulations, the method accurately captures key interface dynamics while reducing inference time to 0.045 seconds per trajectory, corresponding to a speed-up of more than 6×104 relative to Basilisk CFD. These results suggest that AMR refinement structure can serve as a compact and learnable representation for geometry-conditioned surrogate modeling of transient two-phase flows.
A flow surrogate validated on a simple regime is often taken as evidence that the approach will carry to a richer one. We test this assumption on two transient flows under time-varying boundary conditions emulating the process startup: the three-dimensional slurry film in chemical-mechanical planarisation (CMP), a core semiconductor-manufacturing process, and the two-dimensional Karman vortex street (KVS) behind a cylinder. Eight surrogate models are compared on one shared evaluation pipeline, differing in whether they learn the full field or a latent representation, and whether they predict trajectories in one shot or step by step. No single architecture wins both regimes. On the film, a one-shot full-field model reconstructs the process-relevant cumulative wall shear stress to 3.2% relative error. On the wake, a latent autoregressive DeepONet retains 96% of the shedding power that direct and one-shot models damp to almost zero. The deciding axis is the treatment of time. The self-sustained wake requires the phase memory that autoregressive feedback provides, while the boundary-driven film rewards a direct map. Pointwise RMSE picks the wrong model in both regimes, so the evaluation scores five physical questions instead, the field, its structure, invented motion, amplitude, and timing. The trained surrogates answer queries 103 to 104 times faster than the finite-element solver, but the offline cost of the training simulations means they pay off from the first query beyond the training set for CMP and the third for the KVS. The choice of surrogate should follow the dynamical character of the target flow, and its validation should use failure-mode-resolved metrics, since neither the winning architecture nor its validation transfers.
Aerodynamic surrogate models are increasingly used to replace repeated high-fidelity CFD evaluations in many-query design settings, but current approaches still face two important limitations: they often scale poorly to the very large fields arising in realistic 3D aerodynamics, and they rarely produce latent representations that are directly useful for analysis and design. We introduce AeroJEPA, a Joint-Embedding Predictive Architecture for aerodynamic field modeling that addresses both issues. Rather than predicting the full flow field directly from geometry, AeroJEPA predicts a target latent representation of the flow from a context latent representation of the geometry and operating conditions, and optionally reconstructs the field through a continuous implicit decoder. This formulation decouples latent prediction from field resolution while encouraging the latent space to organize semantically. We evaluate AeroJEPA on two complementary datasets: HiLiftAeroML, which stresses the method in a high-fidelity regime with extremely large boundary-layer fields, and SuperWing, which tests large-scale generalization and latent-space optimization over a broad family of transonic wings. Across these benchmarks, AeroJEPA is competitive as a continuous surrogate for aerodynamic fields, scales naturally to high-resolution outputs, and learns context and predicted latents that encode geometry and aerodynamic quantities not used directly as supervision. We further show that the resulting latent space supports controlled interpolation, linear probing, concept-vector arithmetic, and a constrained design latent-optimization experiment. These results suggest that predictive latent learning is a promising direction for scalable and design-meaningful aerodynamic surrogate modeling.
Francisco Giral, Abhijeet Vishwasrao, Andrea Arroyo Ramo +8
While Computational Fluid Dynamics (CFD) provides high-fidelity flow fields for optimizing indoor environments, its computational cost limits rapid exploration. To solve this problem generative surrogates offer better distribution modeling than deterministic networks, but iterative sampling is slow. To enable high-quality, single-pass generation, we adapt the novel generative drifting framework to fluid mechanics. We introduce a conditional architecture that performs drifting in a learned VAE latent space and uses label-aware masking to align generated samples with their boundary conditions. Our label-conditioned model matches iterative diffusion in accuracy and flow consistency while running two orders of magnitude faster. Additionally, we propose a spatial-conditioning variant that establishes a promising path towards generalization to unseen geometries. Ultimately, conditional drifting serves as a highly efficient alternative to diffusion based approaches, unlocking real-time CFD surrogates where inference speed is critical.