Spectrally Safe Neural Operator Warm-Starts for Large-Scale Newton Solvers
Jaemin OhYoungkyu LeeJerome DarbonGeorge Em Karniadakis
Aug 2026
Machine Learning
Abstract
Neural operators are increasingly used to warm-start Newton solvers for nonlinear PDEs, on the premise that a low test error places the initial guess inside the basin of attraction. We show that this premise is unreliable. An operator trained to the relative \(L^2\) error \(O(10^{-3})\) can still produce an initial state in which the discrete Jacobian is indefinite, because the mean-squared training controls error on average while leaving localized pointwise violations of the underlying physics. For a nearly incompressible hyperelasticity problem, we trace this to the predicted volume change: the operator disperses \(\mathrm{det} F\) well away from one, and the resulting Jacobian acquires negative eigenvalues even when the predicted field is visually indistinguishable from the reference. At a small scale, this is a nuisance; at a multi-million degree-of-freedom scale, it is disqualifying, since the conjugate gradient and other Krylov solvers needed for memory-feasible Newton steps assume a definite spectrum. We then show that a short, label-free fine-tuning phase -- penalizing the operator against the discrete energy, with no additional solution data -- shifts the Jacobian spectrum back to positive definite. Combined with an inexact outer loop, this gives a warm-started Newton method that converges across the full loading range where the unregularized operator fails, reaching up to 5.4\(\times\) wall-clock speedup over incremental continuation on a 3D problem with 6.4 million degrees of freedom.
This article investigates several physics-informed and hybrid machine learning strategies that incorporate physics knowledge in experimental data-driven deep-learning models for predicting the bond quality and porosity of fused filament fabrication (FFF) parts. Three types of strategies are explored to incorporate physics constraints and multi-physics FFF simulation results into a deep neural network (DNN), thus ensuring consistency with physical laws: (1) incorporate physics constraints within the loss function of the DNN, (2) use physics model outputs as additional inputs to the DNN model, and (3) pre-train a DNN model with physics model input-output and then update it with experimental data. These strategies help to enforce a physically consistent relationship between bond quality and tensile strength, thus making porosity predictions physically meaningful. Eight different combinations of the above strategies are investigated. The results show how the combination of multiple strategies produces accurate machine learning models even with limited experimental data.
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