R4-i + R5 design pass: RTX_FSI2O_REGEN_ONCE (one patch regeneration per coupled step; dies at step 0 — the registered test is void), the step CSV's subit/dres_y/dres_norm/fx_nodal/fy_nodal columns; the cut predictor's per-face term probe (enable_term_probe) and the curved instrument's exact side/wall viscous integrals — the static convex wall's flat residual is the viscous closure's first-order relative accuracy on O(1/h) fluxes

Co-Authored-By: Claude Fable 5.1 <[email protected]>

crates/specialized/rtx-cfd/src/solvers/incompressible/embedded3/step/cut_predictor.rs

@@ -111,7 +111,8 @@ impl Solver {
         let cv = mask.cv_geometry(c, p);
         // S2-7b: the convective sides' own apertures (host prototype).
         let conv_parts = if mask.conv_sides_exact {
-            mask.cut().and_then(|cut| mask.exact_cv_side_parts(cut, c, p))
+            mask.cut()
+                .and_then(|cut| mask.exact_cv_side_parts(cut, c, p))
         } else {
             None
         };
@@ -159,7 +160,9 @@ impl Solver {
                     // The two half faces' own apertures times their faces' values.
                     let v = |q: [i64; 3]| val(d, q).unwrap_or(0.0);
                     (
-                        0.5 * (parts[d][1].0 * v(add(cell_minus, ed, 1)) + parts[d][1].1 * v(add(cell_plus, ed, 1))) * a_d,
+                        0.5 * (parts[d][1].0 * v(add(cell_minus, ed, 1))
+                            + parts[d][1].1 * v(add(cell_plus, ed, 1)))
+                            * a_d,
                         0.5 * (parts[d][0].0 * v(cell_minus) + parts[d][0].1 * v(cell_plus)) * a_d,
                     )
                 }
@@ -260,7 +263,8 @@ impl Solver {
                     return 0.0;
                 }
                 let cvq = mask.cv_geometry(c, q);
-                let ubq = mask.surface_velocity_at(body, foot_of(q, lat.face_position(c, q)), c, t_old);
+                let ubq =
+                    mask.surface_velocity_at(body, foot_of(q, lat.face_position(c, q)), c, t_old);
                 // Explicit, with a coefficient ∝ 1/d_f: take the gradient from
                 // the faces at least TRANSVERSE_DISTANCE_FLOOR h off the wall —
                 // a FULL neighbour too, over its own distance along the cut
@@ -426,6 +430,23 @@ impl Solver {
             + wall_rhs)
             / (inertia + shear + wall_implicit);
         let v_alpha = fraction * h[c] * area[c];
+        if let Some(tp) = self.term_probe.borrow_mut().as_mut() {
+            let m = rho * v_eff;
+            let terms = [
+                -conv / m,
+                diff / m,
+                (shear * (ub - u_star) - shear_explicit) / m,
+                pressure / m,
+                source / m,
+                (wall_rhs - wall_implicit * u_star) / m,
+                (u_star - u0) / dt,
+            ];
+            let v = &mut tp[c];
+            if v.len() <= idx_f {
+                v.resize(idx_f + 1, [0.0; 7]);
+            }
+            v[idx_f] = terms;
+        }
         (u_star, rho * (v_eff - v_alpha) * (u_star - u0) / dt)
     }
 }

crates/specialized/rtx-cfd/src/solvers/incompressible/embedded3/step/mod.rs

@@ -230,7 +230,8 @@ impl Default for Parameters {
                 .is_ok_and(|v| v == "off"),
             // ON by default since S2-7 (`=h` reproduces the records before it).
             wall_exchange_axis: std::env::var("RTX_E3_WALL_EXCHANGE").map_or(true, |v| v != "h"),
-            wall_exchange_foot: std::env::var("RTX_E3_WALL_EXCHANGE").is_ok_and(|v| v == "axisfoot"),
+            wall_exchange_foot: std::env::var("RTX_E3_WALL_EXCHANGE")
+                .is_ok_and(|v| v == "axisfoot"),
             conv_sides_exact: std::env::var("RTX_E3_CONV_SIDES").is_ok_and(|v| v == "exact"),
             wall_flux_true_normal: std::env::var("RTX_E3_WALL_FLUX").is_ok_and(|v| v == "true"),
             wall_foot_centroid: std::env::var("RTX_E3_WALL_FOOT").is_ok_and(|v| v == "centroid"),
@@ -238,7 +239,8 @@ impl Default for Parameters {
             momentum_volume_tiled: std::env::var("RTX_E3_MOMENTUM_VOLUME")
                 .is_ok_and(|v| v == "tiled"),
             cv_sides_exact: std::env::var("RTX_E3_CV_SIDES").is_ok_and(|v| v == "exact"),
-            wall_order2_centroid: std::env::var("RTX_E3_WALL_ORDER2").is_ok_and(|v| v == "centroid"),
+            wall_order2_centroid: std::env::var("RTX_E3_WALL_ORDER2")
+                .is_ok_and(|v| v == "centroid"),
             // ON by default since S2-5 (`=0` reproduces the records before it).
             diffusion_centroid: std::env::var("RTX_E3_DIFFUSION_CENTROID")
                 .map_or(true, |v| v != "0"),
@@ -269,6 +271,11 @@ pub struct Solver {
     /// cut predictor only): the box route counts it, the operator route
     /// does not.
     pub(super) floor_source: std::cell::Cell<[f64; 3]>,
+    /// R5 design-pass instrument (host cut predictor only): per unknown
+    /// face of each component, the last step's momentum terms as
+    /// accelerations `[−conv, diff, wall shear, pressure, source, solid
+    /// exchange, total] / (ρ V_eff)`; `None` (the default) records nothing.
+    pub(super) term_probe: std::cell::RefCell<Option<[Vec<[f64; 7]>; 3]>>,
     /// The closure lag of the pressure corrections over the last step
     /// (`Mask::closure_lag` summed over the correctors; host path).
     pub(super) pressure_lag: std::cell::Cell<[f64; 3]>,
@@ -308,6 +315,7 @@ impl Solver {
             params,
             momentum_source: None,
             floor_source: std::cell::Cell::new([0.0; 3]),
+            term_probe: std::cell::RefCell::new(None),
             pressure_lag: std::cell::Cell::new([0.0; 3]),
             vol_old: Vec::new(),
             apertures_old: None,
@@ -402,6 +410,16 @@ impl Solver {
         .expect("embedded mask")
     }
 
+    /// R5 instrument: record the cut predictor's momentum terms per face
+    /// from the next step on (host path only; a no-op on the device path).
+    pub fn enable_term_probe(&self) {
+        *self.term_probe.borrow_mut() = Some([Vec::new(), Vec::new(), Vec::new()]);
+    }
+    /// The recorded terms per component face index (see `term_probe`).
+    #[must_use]
+    pub fn term_probe(&self) -> Option<[Vec<[f64; 7]>; 3]> {
+        self.term_probe.borrow().clone()
+    }
     /// The small-cell floor's momentum source over the last step (a force
     /// on the fluid; host cut predictor only, zero otherwise).
     #[must_use]

crates/specialized/rtx-cfd/tests/embedded3_wall_position_curved.rs

@@ -58,9 +58,17 @@ impl Exact {
         let (dx, dy) = (x - CENTRE.0, y - CENTRE.1);
         let r = (dx * dx + dy * dy).sqrt().max(1e-12);
         let ut = if r < R1 {
-            if rigid || !outer_drives() { OMEGA * r } else { 0.0 }
+            if rigid || !outer_drives() {
+                OMEGA * r
+            } else {
+                0.0
+            }
         } else if r > R2 {
-            if rigid || outer_drives() { OMEGA * r } else { 0.0 }
+            if rigid || outer_drives() {
+                OMEGA * r
+            } else {
+                0.0
+            }
         } else {
             self.u_theta(r)
         };
@@ -145,12 +153,14 @@ fn reading(n: usize, rigid: bool) {
     for k in 0..nz {
         for j in 0..ny {
             for i in 0..=nx {
-                field.u[g.uface(k, j, i)] = ex.velocity(i as f64 * h, (j as f64 + 0.5) * h, rigid).0;
+                field.u[g.uface(k, j, i)] =
+                    ex.velocity(i as f64 * h, (j as f64 + 0.5) * h, rigid).0;
             }
         }
         for j in 0..=ny {
             for i in 0..nx {
-                field.v[g.vface(k, j, i)] = ex.velocity((i as f64 + 0.5) * h, j as f64 * h, rigid).1;
+                field.v[g.vface(k, j, i)] =
+                    ex.velocity((i as f64 + 0.5) * h, j as f64 * h, rigid).1;
             }
         }
     }
@@ -287,7 +297,8 @@ fn reading(n: usize, rigid: bool) {
         for i in 0..=nx {
             let f = g.uface(0, j, i);
             if mask.u_kind(f) == rtx_cfd::solvers::incompressible::embedded3::FaceKind::Ghost {
-                let e = (field.u[f] - ex.velocity(i as f64 * h, (j as f64 + 0.5) * h, rigid).0) / (OMEGA * R1);
+                let e = (field.u[f] - ex.velocity(i as f64 * h, (j as f64 + 0.5) * h, rigid).0)
+                    / (OMEGA * R1);
                 gsq += e * e;
                 gn += 1;
                 gmax = gmax.max(e.abs());
@@ -303,7 +314,13 @@ fn reading(n: usize, rigid: bool) {
     );
     println!(
         "  {} n {n}: walls' offsets {off_in:+.4} h (inner) {off_out:+.4} h (outer), positive = inside the fluid; fit A {a:.5} B {b:.5} (exact {:.5} {:.5}, {} points); pressure error of ρ(ΩR1)²: full cells {:.3e} ({cnt}), cut cells {:.3e} mean {:+.3e} ({n_cut}), fraction < 0.5 {:.3e} ({n_small}), ≥ 0.5 {:.3e} ({n_large}), inner wall {:.3e} ({n_in}), outer wall {:.3e} ({n_out}); merged {}; residual {last_res:.1e}",
-        if rigid { "rigid" } else if outer_drives() { "outer-driven" } else { "couette" },
+        if rigid {
+            "rigid"
+        } else if outer_drives() {
+            "outer-driven"
+        } else {
+            "couette"
+        },
         ex.a,
         ex.b,
         pts.len(),
@@ -374,20 +391,29 @@ fn probe(n: usize, rigid: bool) {
     let g = Grid::cubic(nx, ny, nz, h);
     let mut field = Field::new(g);
     solver.initialize(&mut field);
-    let tables = solver.mask().expect("mask").face_shift_tables().expect("shift tables").clone();
+    let tables = solver
+        .mask()
+        .expect("mask")
+        .face_shift_tables()
+        .expect("shift tables")
+        .clone();
     for k in 0..nz {
         for j in 0..ny {
             for i in 0..=nx {
                 let f = g.uface(k, j, i);
                 let t = &tables[0][3 * f..3 * f + 3];
-                field.u[f] = ex.velocity(i as f64 * h + t[0], (j as f64 + 0.5) * h + t[1], rigid).0;
+                field.u[f] = ex
+                    .velocity(i as f64 * h + t[0], (j as f64 + 0.5) * h + t[1], rigid)
+                    .0;
             }
         }
         for j in 0..=ny {
             for i in 0..nx {
                 let f = g.vface(k, j, i);
                 let t = &tables[1][3 * f..3 * f + 3];
-                field.v[f] = ex.velocity((i as f64 + 0.5) * h + t[0], j as f64 * h + t[1], rigid).1;
+                field.v[f] = ex
+                    .velocity((i as f64 + 0.5) * h + t[0], j as f64 * h + t[1], rigid)
+                    .1;
             }
         }
     }
@@ -399,25 +425,119 @@ fn probe(n: usize, rigid: bool) {
     }
     {
         let (body, mask) = (solver.body().expect("body"), solver.mask().expect("mask"));
-        mask.impose(body, &mut field.u, &mut field.v, &mut field.w, solver.time());
+        mask.impose(
+            body,
+            &mut field.u,
+            &mut field.v,
+            &mut field.w,
+            solver.time(),
+        );
     }
     let dt = 0.5 * h * h / (6.0 * MU);
+    // R5 design pass: the predictor's terms per face (viscous group =
+    // diffusion + wall shear + solid exchange, zero on the exact field;
+    // inertial group = convection + pressure + source, zero on the exact
+    // steady field): which group carries the cut layer's residual.
+    solver.enable_term_probe();
     solver.advance(&mut field, dt);
+    let terms = solver.term_probe().expect("term probe");
     let mask = solver.mask().expect("mask");
     let pp = &field.p_prime;
     let a_max = OMEGA * OMEGA * R2;
     let is_cut = |c: usize| mask.vol(c) < 1.0 - 1e-9;
-    // [wall][band]: bands α<¼, ¼–½, ½–¾, ¾–1, full next to cut.
+    // [wall][band]: bands α<¼, ¼–½, ½–¾, ¾–1, full next to cut, interior;
-    let mut acc: [[Vec<f64>; 5]; 2] = Default::default();
+    // per face [total, viscous group, inertial group] / a_max.
+    let mut acc: [[Vec<[f64; 9]>; 6]; 2] = Default::default();
+    // R5 design pass: the EXACT viscous line integrals over the momentum
+    // control volume of a face — the open parts of its four sides (the
+    // side-diffusion group: diffusion + solid exchange) and the wall arc
+    // inside it (the wall-shear group) — from the analytic gradient of the
+    // Taylor–Couette field, as accelerations on the same `V_eff` the
+    // predictor uses. Their sum is the quadrature error (∇²u = 0).
+    let grad = |c: usize, x: f64, y: f64| -> [f64; 2] {
+        let (xp, yp) = (x - CENTRE.0, y - CENTRE.1);
+        let r = (xp * xp + yp * yp).sqrt().max(1e-12);
+        let (f, fp) = if rigid {
+            (OMEGA, 0.0)
+        } else {
+            (ex.a + ex.b / (r * r), -2.0 * ex.b / (r * r * r))
+        };
+        if c == 0 {
+            [-fp * (xp / r) * yp, -f - fp * (yp / r) * yp]
+        } else {
+            [f + fp * (xp / r) * xp, fp * (yp / r) * xp]
+        }
+    };
+    let in_gap = |x: f64, y: f64| {
+        let r = r_of(x, y);
+        (R1..=R2).contains(&r)
+    };
+    let side = |c: usize, x0: f64, y0: f64, x1: f64, y1: f64, n: [f64; 2]| -> f64 {
+        let m = 4096;
+        let len = ((x1 - x0).powi(2) + (y1 - y0).powi(2)).sqrt();
+        let mut s = 0.0;
+        for q in 0..m {
+            let t = (q as f64 + 0.5) / m as f64;
+            let (x, y) = (x0 + t * (x1 - x0), y0 + t * (y1 - y0));
+            if in_gap(x, y) {
+                let g = grad(c, x, y);
+                s += (g[0] * n[0] + g[1] * n[1]) * len / m as f64;
+            }
+        }
+        MU * s
+    };
+    let arc = |c: usize, xa: f64, xb: f64, ya: f64, yb: f64| -> f64 {
+        let mut s = 0.0;
+        let m = 1 << 20;
+        for (r, sign) in [(R1, -1.0), (R2, 1.0)] {
+            for q in 0..m {
+                let th = std::f64::consts::TAU * (q as f64 + 0.5) / m as f64;
+                let (x, y) = (CENTRE.0 + r * th.cos(), CENTRE.1 + r * th.sin());
+                if x >= xa && x < xb && y >= ya && y < yb {
+                    let g = grad(c, x, y);
+                    let n = [sign * th.cos(), sign * th.sin()];
+                    s += (g[0] * n[0] + g[1] * n[1]) * r * std::f64::consts::TAU / m as f64;
+                }
+            }
+        }
+        MU * s
+    };
+    // (side-diffusion, wall-shear) exact accelerations for the face of
+    // component `c` whose CV is the box [xa, xb] × [ya, yb], aperture `a`.
+    let exact_terms = |c: usize, xa: f64, xb: f64, ya: f64, yb: f64, a: f64| -> (f64, f64) {
+        let d = side(c, xa, ya, xa, yb, [-1.0, 0.0])
+            + side(c, xb, ya, xb, yb, [1.0, 0.0])
+            + side(c, xa, ya, xb, ya, [0.0, -1.0])
+            + side(c, xa, yb, xb, yb, [0.0, 1.0]);
+        let w = arc(c, xa, xb, ya, yb);
+        let v_eff = a.max(0.1) * h * h * h;
+        (d * h / (RHO * v_eff), w * h / (RHO * v_eff))
+    };
     let bin_of = |a: f64, near: bool| -> Option<usize> {
         if a < 1.0 {
             Some(((a * 4.0).floor() as usize).min(3))
         } else if near {
             Some(4)
         } else {
-            None
+            Some(5)
         }
     };
+    // [total, viscous group, inertial group, diffusion, wall shear, solid exchange] / a_max.
+    // …, then the side-diffusion error (diff + exch − exact), the wall-shear
+    // error (shear − exact) and the exact sum (the quadrature's own error).
+    let groups = |t: &[f64; 7], total: f64, exact: (f64, f64)| -> [f64; 9] {
+        [
+            total / a_max,
+            (t[1] + t[2] + t[5]) / a_max,
+            (t[0] + t[3] + t[4]) / a_max,
+            t[1] / a_max,
+            t[2] / a_max,
+            t[5] / a_max,
+            (t[1] + t[5] - exact.0) / a_max,
+            (t[2] - exact.1) / a_max,
+            (exact.0 + exact.1) / a_max,
+        ]
+    };
     let wall_of = |x: f64, y: f64| usize::from(r_of(x, y) >= 0.5 * (R1 + R2));
     for j in 0..ny {
         for i in 1..nx {
@@ -426,9 +546,24 @@ fn probe(n: usize, rigid: bool) {
                 continue;
             }
             let (cm, cp) = (g.cell(0, j, i - 1), g.cell(0, j, i));
-            let Some(b) = bin_of(mask.a_u(f), is_cut(cm) || is_cut(cp)) else { continue };
+            let Some(b) = bin_of(mask.a_u(f), is_cut(cm) || is_cut(cp)) else {
+                continue;
+            };
             let star = field.u[f] + (dt / RHO) * mask.grad_weight(0, f) * (pp[cp] - pp[cm]) / h;
-            acc[wall_of(i as f64 * h, (j as f64 + 0.5) * h)][b].push((star - field.u_old[f]) / dt / a_max);
+            let t = terms[0].get(f).copied().unwrap_or([0.0; 7]);
+            let exact = exact_terms(
+                0,
+                (i as f64 - 0.5) * h,
+                (i as f64 + 0.5) * h,
+                j as f64 * h,
+                (j as f64 + 1.0) * h,
+                mask.a_u(f),
+            );
+            acc[wall_of(i as f64 * h, (j as f64 + 0.5) * h)][b].push(groups(
+                &t,
+                (star - field.u_old[f]) / dt,
+                exact,
+            ));
         }
     }
     for j in 1..ny {
@@ -438,9 +573,24 @@ fn probe(n: usize, rigid: bool) {
                 continue;
             }
             let (cm, cp) = (g.cell(0, j - 1, i), g.cell(0, j, i));
-            let Some(b) = bin_of(mask.a_v(f), is_cut(cm) || is_cut(cp)) else { continue };
+            let Some(b) = bin_of(mask.a_v(f), is_cut(cm) || is_cut(cp)) else {
+                continue;
+            };
             let star = field.v[f] + (dt / RHO) * mask.grad_weight(1, f) * (pp[cp] - pp[cm]) / h;
-            acc[wall_of((i as f64 + 0.5) * h, j as f64 * h)][b].push((star - field.v_old[f]) / dt / a_max);
+            let t = terms[1].get(f).copied().unwrap_or([0.0; 7]);
+            let exact = exact_terms(
+                1,
+                i as f64 * h,
+                (i as f64 + 1.0) * h,
+                (j as f64 - 0.5) * h,
+                (j as f64 + 0.5) * h,
+                mask.a_v(f),
+            );
+            acc[wall_of((i as f64 + 0.5) * h, j as f64 * h)][b].push(groups(
+                &t,
+                (star - field.v_old[f]) / dt,
+                exact,
+            ));
         }
     }
     let scale = RHO * (OMEGA * R1).powi(2);
@@ -464,23 +614,55 @@ fn probe(n: usize, rigid: bool) {
                 continue;
             }
             let e = (pp[c] - lvl) / scale;
-            let w = if is_cut(c) { wall_of((i as f64 + 0.5) * h, (j as f64 + 0.5) * h) } else { 2 };
+            let w = if is_cut(c) {
+                wall_of((i as f64 + 0.5) * h, (j as f64 + 0.5) * h)
+            } else {
+                2
+            };
             psq[w] += e * e;
             pn[w] += 1;
         }
     }
-    let rms = |v: &[f64]| (v.iter().map(|x| x * x).sum::<f64>() / v.len().max(1) as f64).sqrt();
+    let rms = |v: &[[f64; 9]], k: usize| {
-    let names = ["α<¼", "¼–½", "½–¾", "¾–1", "full next to cut"];
+        (v.iter().map(|x| x[k] * x[k]).sum::<f64>() / v.len().max(1) as f64).sqrt()
-    let mode = if rigid { "rigid" } else if outer_drives() { "outer-driven" } else { "couette" };
+    };
+    let names = ["α<¼", "¼–½", "½–¾", "¾–1", "full next to cut", "interior"];
+    let mode = if rigid {
+        "rigid"
+    } else if outer_drives() {
+        "outer-driven"
+    } else {
+        "couette"
+    };
     for (w, wname) in ["inner wall", "outer wall"].iter().enumerate() {
         let mut line = format!("  probe {mode} n {n} {wname}:");
         for (b, name) in names.iter().enumerate() {
-            line += &format!(" {name} {} rms {:.3e};", acc[w][b].len(), rms(&acc[w][b]));
+            line += &format!(
+                " {name} {} rms {:.3e} (visc {:.3e} inert {:.3e}; diff {:.3e} shear {:.3e} exch {:.3e}; ERR sides {:.3e} wall {:.3e} quad {:.1e});",
+                acc[w][b].len(),
+                rms(&acc[w][b], 0),
+                rms(&acc[w][b], 1),
+                rms(&acc[w][b], 2),
+                rms(&acc[w][b], 3),
+                rms(&acc[w][b], 4),
+                rms(&acc[w][b], 5),
+                rms(&acc[w][b], 6),
+                rms(&acc[w][b], 7),
+                rms(&acc[w][b], 8)
+            );
         }
-        line += &format!(" p' at its cut cells {:.3e} ({})", (psq[w] / pn[w].max(1) as f64).sqrt(), pn[w]);
+        line += &format!(
+            " p' at its cut cells {:.3e} ({})",
+            (psq[w] / pn[w].max(1) as f64).sqrt(),
+            pn[w]
+        );
         println!("{line}");
     }
-    println!("  probe {mode} n {n} interior p' {:.3e} ({})", (psq[2] / pn[2].max(1) as f64).sqrt(), pn[2]);
+    println!(
+        "  probe {mode} n {n} interior p' {:.3e} ({})",
+        (psq[2] / pn[2].max(1) as f64).sqrt(),
+        pn[2]
+    );
 }
 
 #[test]

crates/specialized/rtx-fsi/tests/fsi2_harness/overset.rs

@@ -240,6 +240,15 @@ pub struct OversetFluid {
     /// The last fluid step's mass defects (patch acceptor ring, background
     /// fringe) and the patch's max divergence.
     pub last_defects: Cell<(f64, f64, f64)>,
+    /// R4-i `RTX_FSI2O_REGEN_ONCE`: one patch regeneration per coupled
+    /// step — the first pass's meshes (one per substep) are reused by every
+    /// later subiteration of the same step (the wall polygon and velocity
+    /// still follow the candidate). Active between `begin_coupled_step`
+    /// calls only; `restore` rewinds the cursor to the step's first substep.
+    pub regen_once: bool,
+    pub regen_hold: bool,
+    pub regen_cache: Vec<rtx_cfd::mesh::PatchMesh>,
+    pub regen_cursor: usize,
 }
 
 impl OversetFluid {
@@ -503,6 +512,10 @@ impl OversetFluid {
             correctors_total: Cell::new(0),
             last_d: zero_d,
             last_defects: Cell::new((0.0, 0.0, 0.0)),
+            regen_once: std::env::var("RTX_FSI2O_REGEN_ONCE").is_ok(),
+            regen_hold: false,
+            regen_cache: Vec::new(),
+            regen_cursor: 0,
             warm_base: None,
             warm_sweeps,
         })
@@ -918,6 +931,12 @@ impl OversetFluid {
             self.last_d = d.to_vec();
             return Ok(());
         }
+        if self.regen_once && self.regen_hold && self.regen_cursor < self.regen_cache.len() {
+            let mesh = self.regen_cache[self.regen_cursor].clone();
+            self.regen_cursor += 1;
+            self.last_d = d.to_vec();
+            return self.solver.set_patch_mesh(mesh);
+        }
         let mesh = match self.patch_for(d) {
             Ok(m) => m,
             Err(e) => {
@@ -925,10 +944,22 @@ impl OversetFluid {
                 return Err(e);
             }
         };
+        if self.regen_once && self.regen_hold {
+            self.regen_cache.push(mesh.clone());
+            self.regen_cursor += 1;
+        }
         self.last_d = d.to_vec();
         self.solver.set_patch_mesh(mesh)
     }
 
+    /// R4-i: a new coupled step begins — the first pass regenerates, the
+    /// later passes reuse (`RTX_FSI2O_REGEN_ONCE`; a no-op otherwise).
+    pub fn begin_coupled_step(&mut self) {
+        self.regen_hold = self.regen_once;
+        self.regen_cache.clear();
+        self.regen_cursor = 0;
+    }
+
     /// The last geometry, for the offline reproduction
     /// (`patch_cylinder_flag_deformed.rs`, `RTX_CF_EDGES_FILE`): one edge
     /// per block, `x y` per line, when `RTX_FSI2O_DUMP_DIR` is set.
@@ -1198,6 +1229,7 @@ impl OversetFluid {
         let t0 = std::time::Instant::now();
         self.solver.restore(&saved.0);
         self.field = saved.1.clone();
+        self.regen_cursor = 0;
         self.t_restore
             .set(self.t_restore.get() + t0.elapsed().as_secs_f64());
     }

crates/specialized/rtx-fsi/tests/fsi2_harness/overset_march.rs

@@ -137,6 +137,11 @@ pub fn run_march_overset(case: BenchmarkCase, config: &OversetMarchConfig) -> Ov
         std::env::var("RTX_FSI2O_FICT_MASS").unwrap_or_else(|_| "0".into()),
         std::env::var("RTX_FSI2O_ROBIN_ALPHA").unwrap_or_else(|_| "0".into()),
     );
+    if std::env::var("RTX_FSI2O_REGEN_ONCE").is_ok() {
+        println!(
+            "  patch regeneration: ONCE per coupled step (R4-i, RTX_FSI2O_REGEN_ONCE): the first pass's mesh is reused by the later subiterations"
+        );
+    }
 
     // Phase 1: rigid flag to t_release (`RTX_FSI2O_LOAD=dir` replaces the
     // march with the saved state; `RTX_FSI2O_SAVE=dir` saves it).
@@ -399,7 +404,11 @@ pub fn run_march_overset(case: BenchmarkCase, config: &OversetMarchConfig) -> Ov
     // cell imbalance.
     let mut step_csv = std::env::var("RTX_FSI2O_STEP_CSV").ok().map(|p| {
         let mut f = std::fs::File::create(p).expect("step csv");
-        writeln!(f, "t,ux,uy,drag,lift,defect_patch,defect_bg,patch_div").unwrap();
+        // R4-i columns: the step's subiterations, the last pass's signed
+        // y-residual Σ_k (d_new − d_candidate)_y and its norm, and the
+        // nodal load the structure was given (Σ F_x, Σ F_y) — against the
+        // wall-integral force of the same state (drag, lift).
+        writeln!(f, "t,ux,uy,drag,lift,defect_patch,defect_bg,patch_div,subit,dres_y,dres_norm,fx_nodal,fy_nodal").unwrap();
         f
     });
     let (t_fluid, t_structure) = (std::cell::Cell::new(0.0_f64), std::cell::Cell::new(0.0_f64));
@@ -433,6 +442,7 @@ pub fn run_march_overset(case: BenchmarkCase, config: &OversetMarchConfig) -> Ov
         if robin_alpha > 0.0 {
             robin_datum.replace(fluid.borrow().inner_tractions());
         }
+        fluid.borrow_mut().begin_coupled_step();
         let saved = fluid.borrow().snapshot();
         type PassResult = (DynamicState, Vec<(NodeId, Vector3<f64>)>, f64, usize);
         let latest: RefCell<Option<PassResult>> = RefCell::new(None);
@@ -498,6 +508,7 @@ pub fn run_march_overset(case: BenchmarkCase, config: &OversetMarchConfig) -> Ov
         let tol_step = cfg.tol_floor.max(cfg.rtol * increment);
         let retry_at = (5.0 * tol_step).max(0.1 * increment);
         let acceptable = (cfg.stall_accept * tol_step).max(0.1 * increment);
+        let mut step_iterations = 0usize;
         let mut outcome = if let Some(iqn) = iqn.as_mut() {
             iqn.set_tolerance(tol_step).unwrap();
             iqn.solve(&d_predicted, pass)
@@ -533,6 +544,7 @@ pub fn run_march_overset(case: BenchmarkCase, config: &OversetMarchConfig) -> Ov
             Ok(c) => {
                 total_subiterations += c.iterations;
                 max_subiterations = max_subiterations.max(c.iterations);
+                step_iterations = c.iterations;
             }
             Err(
                 rtx_fsi::FsiError::CouplingNotConverged {
@@ -549,6 +561,7 @@ pub fn run_march_overset(case: BenchmarkCase, config: &OversetMarchConfig) -> Ov
                 worst_stall = worst_stall.max(residual);
                 total_subiterations += iterations;
                 max_subiterations = max_subiterations.max(iterations);
+                step_iterations = iterations;
             }
             Err(e) => {
                 println!(
@@ -560,6 +573,25 @@ pub fn run_march_overset(case: BenchmarkCase, config: &OversetMarchConfig) -> Ov
             }
         }
         let (new_state, nodal, conservation, faces) = latest.borrow_mut().take().expect("pass ran");
+        // R4-i: the last pass's residual (the structure's answer against the
+        // candidate the fluid's committed state sits at) and the nodal load.
+        let (dres_y, dres_norm, fx_nodal, fy_nodal) = {
+            let d_new = extract(&new_state);
+            let d_cand = &fluid.borrow().last_d;
+            let mut sy = 0.0_f64;
+            let mut n2 = 0.0_f64;
+            for k in 0..d_new.len() / 2 {
+                sy += d_new[2 * k + 1] - d_cand[2 * k + 1];
+                n2 += (d_new[2 * k] - d_cand[2 * k]).powi(2)
+                    + (d_new[2 * k + 1] - d_cand[2 * k + 1]).powi(2);
+            }
+            let (mut fx, mut fy) = (0.0_f64, 0.0_f64);
+            for (_, f) in &nodal {
+                fx += f.x;
+                fy += f.y;
+            }
+            (sy, n2.sqrt(), fx, fy)
+        };
         flag_state = new_state;
         committed_nodal = nodal;
         prev_area.set(fluid.borrow().shared.read().unwrap().area());
@@ -590,7 +622,7 @@ pub fn run_march_overset(case: BenchmarkCase, config: &OversetMarchConfig) -> Ov
             let (dp, db, pd) = fluid.borrow().last_defects.get();
             writeln!(
                 f,
-                "{t_now:.6},{ux:.6e},{uy:.6e},{drag_now:.6e},{lift_now:.6e},{dp:.3e},{db:.3e},{pd:.3e}"
+                "{t_now:.6},{ux:.6e},{uy:.6e},{drag_now:.6e},{lift_now:.6e},{dp:.3e},{db:.3e},{pd:.3e},{step_iterations},{dres_y:.3e},{dres_norm:.3e},{fx_nodal:.6e},{fy_nodal:.6e}"
             )
             .unwrap();
         }