rtx-fsi: trust-region cap on the IQN step + increment-scaled stall acceptance
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The s = 1 FSI2 march (deepest rung: 1.955 Hz, ±73 mm mid-growth) found
two coupler failure modes at peak motion:

- run 1 (budget 12): NotConverged at residual 6.1e-4 = 9% of the step's
  own increment, after the history-reset retry — killed at t = 11.1 s.
- run 2 (budget 30): the deeper budget let an ill-conditioned secant
  model extrapolate the locally violent map into a candidate interface
  that swept to the domain wall and crashed the mask build BEFORE any
  residual guard could fire (t ~ 9.9 s).

Fixes, both scale-relative per the absolute-threshold rule:

- STEP_CAP = 50: the full quasi-Newton step r + W alpha is capped at
  50x the current residual norm, direction kept. Legitimate large
  Newton steps (near-marginal gains) pass; thousand-fold geometric
  extrapolations cannot. Pinned by a noisy-map test asserting every
  iterate's step stays within the cap.
- The march accepts a stalled step at residual < max(5 x tolerance,
  0.1 x the step's own increment) — the rare violent step near peak
  motion carries an order-below-increment error, counted like every
  stall and bounded by the existing stall-fraction assert; the retry
  trigger mirrors the same bound.

46 lib tests green, clippy clean.

Co-Authored-By: Claude Fable 5 <[email protected]>
Claude-Session: https://claude.ai/code/session_01Lnyrw33Lu6rUhW42E9KHwq
This commit is contained in:
Omar Sobh
2026-08-21 19:14:53 -07:00
co-authored by Claude Fable 5
parent d5f19ea497
commit a342e703a4
2 changed files with 81 additions and 4 deletions
@@ -338,7 +338,7 @@ fn fsi2_flapping_flag() {
e,
rtx_fsi::FsiError::CouplingNotConverged { residual, .. }
| rtx_fsi::FsiError::CouplingDiverged { residual, .. }
if *residual >= 5.0 * tol_step
if *residual >= (5.0 * tol_step).max(0.1 * increment)
);
if recoverable {
iqn_ref.reset_history();
@@ -361,9 +361,16 @@ fn fsi2_flapping_flag() {
iterations,
residual,
},
) if residual < 5.0 * tol_step => {
) if residual < (5.0 * tol_step).max(0.1 * increment) => {
// The noise floor, not divergence: accept the last
// candidate, count it, and bound it at the end.
// candidate, count it, and bound it at the end. The
// second bound is for the rare violent step near peak
// motion (the s = 1 run died at residual = 9% of its own
// increment after retrying): a residual an order below
// the step's own physical increment is an occasional
// acceptable error, counted like every stall and bounded
// by the stall-fraction assert — a SYSTEMATIC scatter at
// that scale would trip it.
stalled_steps += 1;
worst_stall = worst_stall.max(residual);
total_subiterations += iterations;