Do Better Scores Mean Better Physics? Physics-Grounded Explanations for Sim2Real Neural Operators

Neural operator models trained on simulation data often lose accuracy when applied to experimental measurements due to the sim-to-real gap. Standard fine-tuning with limited real data can reduce this gap, but it may also damage the core physics-relevant representations learned during pretraining. Although knowledge-preserving adaptation has been widely investigated in vision or language tasks, it remains unclear whether these methods are suitable for neural operators whose architectures and protected knowledge are fundamentally different. Neural operators need to preserve core-scale physical structures rather than semantic or visual features. We propose PhysGuard, a physics-preserving framework for accurate sim-to-real adaptation of neural operators. Specifically, PhysGuard uses the empirical Fisher Information Matrix computed on simulation data to identify physics-critical parameter directions, then restricts fine-tuning updates to directions that do not interfere with them. A layer-wise Gram-matrix formulation makes this efficient for models with millions of parameters, while an adaptive threshold automatically determines the protected subspace size. A spectral probe experiment shows that the dominant Fisher directions are strongly associated with low-frequency output structures. Experiments on benchmark across four neural operator architectures and different physical systems show that PhysGuard performs strongly on most evaluation metrics compared to baselines. The benefits are most evident under severe domain shift, where it reduces low-frequency error by up to 32% compared to standard fine-tuning while maintaining adaptability. Our code is available at https://github.com/ZhouChaunge/PhysGuard.

Autoregressive scientific forecasters often enforce physical or structural constraints by repairing each predicted state before feeding it back into the model. However, it remains unclear when stronger physical rule enforcement becomes reliable and when it becomes a source of distribution shift. We study this question through operator exactness, meaning whether the repair map is the identity on the target manifold and is aligned with the target geometry. We compare raw forecasting, post hoc repair, and in-loop repair across periodic incompressible Navier--Stokes, non-periodic CFDBench flows, and a hierarchical-forecasting support task. In the exact periodic regime, Fourier projection substantially improves rollout accuracy. On the NS-128 benchmark, a strong Raw-FNO has a final-step rollout MSE at horizon 100 of $(9.390 \pm 6.290)\times 10^{-5}$, and post hoc and in-loop projection reduce it to $(1.130 \pm 0.165)\times 10^{-6}$ and $(5.370 \pm 0.113)\times 10^{-7}$. However, once an exact projection is unavailable and only approximate boundary-preserving cleanup is available, the ordering changes. Across cavity, tube, dam, and cylinder flow, stronger Poisson-based cleanup can reduce divergence while worsening rollout error; target-distortion MSE predicts this harm far better than a linear-system residual. Controlled mismatch, screened cleanup, adaptive gating, and external-backbone checks show that the best approximate-regime operating point can be raw or near-identity. Hierarchical forecasting gives the same broader pattern. Exact forecast reconciliation is a stable baseline, whereas blended top-down repair, a validation-tuned interpolation toward historical-proportion top-down reconciliation, is dataset-dependent. Thus, constraint enforcement should be benchmarked by operator--data alignment before enforcement strength.

Neural surrogate models for physical simulations are trained on discretized samples of continuous domains, where the induced empirical measure leads to uneven supervision, biasing optimization and causing spatial inconsistencies in physical fidelity. To mitigate this measure-induced bias, we propose M$^3$ (Multi-scale Morton Measure), a scalable framework that balances training measures by partitioning space according to physical variation and allocating supervision across multiple scales. Applied to three industrial-scale datasets with diverse discretizations, M$^3$ consistently improves predictions in the continuous physical domain, achieving up to 4.7$\times$ lower error in large-scale volumetric cases. These gains persist under aggressive subsampling (160M $\rightarrow$ 16M $\rightarrow$ 1.6M points), where M$^3$-trained models outperform those trained on higher-resolution data, reducing physics-weighted relative $L_2$ error by 3--4$\times$ and the corresponding MSE by up to 13$\times$. These results highlight data distribution as a key factor in operator learning and position M$^3$ as a scalable, data-efficient approach for physically consistent modeling. Code is available at https://github.com/PhysDataRefine/M3.