Peter Sharpe

Neil Ashton, Adam Clark, Liam Heidt et al.

This paper describes the first-ever open-source high-fidelity CFD dataset of a high-lift aircraft for the purpose of AI surrogate model development. The dataset is composed of 1800 samples, arising from 180 geometry variants and 10 angles of attack for the high-lift NASA Common Research Model (CRM) geometry, used within the AIAA High-Lift Prediction Workshop series. One of the novelties of this dataset is the use of a GPU-accelerated high-fidelity explicit, wall-modeled LES approach for each simulation, using solution-adapted grids between 300M and 500M cells. This ensures the greatest possible accuracy given known challenges in steady-state RANS approaches for these portions of the flight envelope. The entire dataset (geometries, time-averaged volume and surface variables and integral forces) are available, free of charge with a permissive open-source license (CC-BY-4.0). By making this data publicly available, we aim to accelerate the research and development of AI surrogate modeling within the aerospace industry.

Peter Sharpe, R. John Hansman

NeuralFoil is an open-source Python-based tool for rapid aerodynamics analysis of airfoils, similar in purpose to XFoil. Speedups ranging from 8x to 1,000x over XFoil are demonstrated, after controlling for equivalent accuracy. NeuralFoil computes both global and local quantities (lift, drag, velocity distribution, etc.) over a broad input space, including: an 18-dimensional space of airfoil shapes, possibly including control deflections; a 360 degree range of angles of attack; Reynolds numbers from $10^2$ to $10^{10}$; subsonic flows up to the transonic drag rise; and with varying turbulence parameters. Results match those of XFoil closely: the mean relative error of drag is 0.37% on simple cases, and remains as low as 2.0% on a test dataset with numerous post-stall and transitional cases. NeuralFoil facilitates gradient-based design optimization, due to its $C^\infty$-continuous solutions, automatic-differentiation-compatibility, and bounded computational cost without non-convergence issues. NeuralFoil is a hybrid of physics-informed machine learning techniques and analytical models. Here, physics information includes symmetries that are structurally embedded into the model architecture, feature engineering using domain knowledge, and guaranteed extrapolation to known limit cases. This work also introduces a new approach for surrogate model uncertainty quantification that enables robust design optimization. This work discusses the methodology and performance of NeuralFoil with several case studies, including a practical airfoil design optimization study including both aerodynamic and non-aerodynamic constraints. Here, NeuralFoil optimization is able to produce airfoils nearly identical in performance and shape to expert-designed airfoils within seconds; these computationally-optimized airfoils provide a useful starting point for further expert refinement.

Kaustubh Tangsali, Rishikesh Ranade, Mohammad Amin Nabian et al.

In this paper, we introduce a benchmarking framework within the open-source NVIDIA PhysicsNeMo-CFD framework designed to systematically assess the accuracy, performance, scalability, and generalization capabilities of AI models for automotive aerodynamics predictions. The open extensible framework enables incorporation of a diverse set of metrics relevant to the Computer-Aided Engineering (CAE) community. By providing a standardized methodology for comparing AI models, the framework enhances transparency and consistency in performance assessment, with the overarching goal of improving the understanding and development of these models to accelerate research and innovation in the field. To demonstrate its utility, the framework includes evaluation of both surface and volumetric flow field predictions on three AI models: DoMINO, X-MeshGraphNet, and FIGConvNet using the DrivAerML dataset. It also includes guidelines for integrating additional models and datasets, making it extensible for physically consistent metrics. This benchmarking study aims to enable researchers and industry professionals in selecting, refining, and advancing AI-driven aerodynamic modeling approaches, ultimately fostering the development of more efficient, accurate, and interpretable solutions in automotive aerodynamics

Peter Sharpe, Rishikesh Ranade, Kaustubh Tangsali et al.

Transient computational fluid dynamics (CFD) simulations are essential for many industrial applications, but suffer from high compute costs relative to steady-state simulations. This is due to the need to: (a) reach statistical steadiness by physically advecting errors in the initial field sufficiently far downstream, and (b) gather a sufficient sample of fluctuating flow data to estimate time-averaged quantities of interest. We present a machine learning-based initialization method that aims to reduce the cost of transient solve by providing more accurate initial fields. Through a case study in automotive aerodynamics on a 17M-cell unsteady incompressible RANS simulation, we evaluate three proposed ML-based initialization strategies against existing methods. Here, we demonstrate 50% reductions in time-to-convergence compared to traditional uniform and potential flow-based initializations. Two ML-based initialization strategies are recommended for general use: (1) a hybrid method combining ML predictions with potential flow solutions, and (2) an approach integrating ML predictions with uniform flow. Both strategies enable CFD solvers to achieve convergence times comparable to computationally-expensive steady RANS initializations, while requiring far less wall-clock time to compute the initialization field. Notably, these improvements are achieved using an ML model trained on a different dataset of diverse automotive geometries, demonstrating generalization capabilities relevant to specific industrial application areas. Because this Hybrid-ML workflow only modifies the inputs to an existing CFD solver, rather than modifying the solver itself, it can be applied to existing CFD workflows with relatively minimal changes; this provides a practical approach to accelerating industrial CFD simulations using existing ML surrogate models.

Peter Sharpe

We introduce GLOBE, a new neural surrogate for homogeneous PDEs that draws inductive bias from boundary-element methods and equivariant ML. GLOBE represents solutions as superpositions of learnable Green's-function-like kernels evaluated from boundary faces to targets, composed across multiscale branches and communication hyperlayers. The architecture is translation-, rotation-, and parity-equivariant; discretization-invariant in the fine-mesh limit; and units-invariant via rigorous nondimensionalization. An explicit far-field decay envelope stabilizes extrapolation, boundary-to-boundary hyperlayer communication mediates long-range coupling, and the all-to-all boundary-to-target evaluation yields a global receptive field that respects PDE information flow, even for elliptic PDEs. On AirFRANS (steady incompressible RANS over NACA airfoils), GLOBE achieves substantial accuracy improvements. On the "Full" split, it reduces mean-squared error by roughly 200x on all fields relative to the dataset's reference baselines, and roughly 50x relative to the next-best-performing model. In the "Scarce" split, it achieves over 100x lower error on velocity and pressure fields and over 600x lower error on surface pressure than Transolver. Qualitative results show sharp near-wall gradients, coherent wakes, and limited errors under modest extrapolation in Reynolds number and angle of attack. In addition to this accuracy, the model is quite compact (117k parameters), and fields can be evaluated at arbitrary points during inference. We also demonstrate the ability to train and predict with non-watertight meshes, which has strong practical implications. These results show that rigorous physics- and domain-inspired inductive biases can achieve large gains in accuracy, generalizability, and practicality for ML-based PDE surrogates for industrial computer-aided engineering (CAE).

Peter Sharpe

When numerically evaluating a function's gradient, sparsity detection can enable substantial computational speedups through Jacobian coloring and compression. However, sparsity detection techniques for black-box functions are limited, and existing finite-difference-based methods suffer from false negatives due to coincidental zero gradients. These false negatives can silently corrupt gradient calculations, leading to difficult-to-diagnose errors. We introduce NaN-propagation, which exploits the universal contamination property of IEEE 754 Not-a-Number values to trace input-output dependencies through floating-point numerical computations. By systematically contaminating inputs with NaN and observing which outputs become NaN, the method reconstructs conservative sparsity patterns that eliminate a major source of false negatives. We demonstrate this approach on an aerospace wing weight model, achieving a 1.52x speedup while uncovering dozens of dependencies missed by conventional methods -- a significant practical improvement since gradient computation is often the bottleneck in optimization workflows. The technique leverages IEEE 754 compliance to work across programming languages and math libraries without requiring modifications to existing black-box codes. Furthermore, advanced strategies such as NaN payload encoding via direct bit manipulation enable faster-than-linear time complexity, yielding speed improvements over existing black-box sparsity detection methods. Practical algorithms are also proposed to mitigate challenges from branching code execution common in engineering applications.