Data-Driven Design Optimization of Streaming-Potential-Mediated Electrokinetic Transport of Viscoelastic Fluids in Microchannels

Droplet impact on solid surfaces is a complex fluid dynamics problem with applications in spray cooling, inkjet printing, and pharmaceutical processing. Although numerical simulations are widely used to investigate these dynamics, their computational cost becomes significant when multiple parametric variations are considered. In this work, we investigate the use of a Video Vision Transformer (ViViT) architecture to predict the temporal evolution of viscoelastic droplets impacting solid surfaces using volume fraction fields obtained from the Volume of Fluid (VOF) method. In Newtonian fluids, impact dynamics are mainly characterized by the Reynolds number $Re$, representing the ratio of inertial to viscous forces, and the Weber number $We$, representing the ratio of inertial to surface tension forces. For viscoelastic fluids, additional parameters are required to account for elastic effects, namely the solvent viscosity ratio $β$ and the Weissenberg number $Wi$, increasing simulation complexity and cost. Instead of simulating the entire droplet dynamics, the proposed approach uses only the initial 10% to 20% of the simulation to predict the remaining evolution. Depending on the prediction configuration, this strategy reduces computational cost by approximately 80% to 90% compared to full numerical simulations. The ViViT produces physically consistent predictions across different parameters and prediction horizons, successfully capturing both spreading and bouncing regimes while preserving geometric features and structural similarity. Since volume fraction fields can also be extracted from experimental videos, the proposed framework could be extended to incorporate experimental data during training, potentially improving the physical fidelity of the predicted dynamics.

The ability to model mechanics of soft materials under flowing conditions is key in designing and engineering processes and materials with targeted properties. This generally requires solution of internal stress tensor, related to the deformation tensor through nonlinear and history-dependent constitutive models. Traditional numerical methods for non-Newtonian fluid dynamics often suffer from prohibitive computational demands and poor scalability to new problem instances. Developments in data-driven methods have mitigated some limitations but still require retraining across varied physical conditions. In this work, we introduce Rheological Operator Transformer (RheOFormer), a generative operator learning method leveraging self-attention to efficiently learn different spatial interactions and features of complex fluid flows. We benchmark RheOFormer across a range of different viscometric and non-viscometric flows with different types of viscoelastic and elastoviscoplastic mechanics in complex domains against ground truth solutions. Our results demonstrate that RheOFormer can accurately learn both scalar and tensorial nonlinear mechanics of different complex fluids and predict the spatio-temporal evolution of their flows, even when trained on limited datasets. Its strong generalization capabilities and computational efficiency establish RheOFormer as a robust neural surrogate for accelerating predictive complex fluid simulations, advancing data-driven experimentation, and enabling real-time process optimization across a wide range of applications.

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 $10^3$ to $10^4$ 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.