Hybrid Fourier Neural Operator for Surrogate Modeling of Laser Processing with a Quantum-Circuit Mixer

Data-driven surrogates can replace expensive multiphysics solvers for parametric PDEs, yet building compact, accurate neural operators for three-dimensional problems remains challenging: in Fourier Neural Operators, dense mode-wise spectral channel mixing scales linearly with the number of retained Fourier modes, inflating parameter counts and limiting real-time deployability. We introduce HQ-LP-FNO, a hybrid quantum-classical FNO that replaces a configurable fraction of these dense spectral blocks with a compact, mode-shared variational quantum circuit mixer whose parameter count is independent of the Fourier mode budget. A parameter-matched classical bottleneck control is co-designed to provide a rigorous evaluation framework. Evaluated on three-dimensional surrogate modeling of high-energy laser processing, coupling heat transfer, melt-pool convection, free-surface deformation, and phase change, HQ-LP-FNO reduces trainable parameters by 15.6% relative to a classical baseline while lowering phase-fraction mean absolute error by 26% and relative temperature MAE from 2.89% to 2.56%. A sweep over the quantum-channel budget reveals that a moderate VQC allocation yields the best temperature metrics across all tested configurations, including the fully classical baseline, pointing toward an optimal classical-quantum partitioning. The ablation confirms that mode-shared mixing, naturally implemented by the VQC through its compact circuit structure, is the dominant contributor to these improvements. A noisy-simulator study under backend-calibrated noise from ibm-torino confirms numerical stability of the quantum mixer across the tested shot range. These results demonstrate that VQC-based parameter-efficient spectral mixing can improve neural operator surrogates for complex multiphysics problems and establish a controlled evaluation protocol for hybrid quantum operator learning in practice.

A Fast and Generalizable Fourier Neural Operator-Based Surrogate for Melt-Pool Prediction in Laser Processing

High-fidelity simulations of laser welding capture complex thermo-fluid phenomena, including phase change, free-surface deformation, and keyhole dynamics, however their computational cost limits large-scale process exploration and real-time use. In this work we present the Laser Processing Fourier Neural Operator (LP-FNO), a Fourier Neural Operator (FNO) based surrogate model that learns the parametric solution operator of various laser processes from multiphysics simulations generated with FLOW-3D WELD (registered trademark). Through a novel approach of reformulating the transient problem in the moving laser frame and applying temporal averaging, the system results in a quasi-steady state setting suitable for operator learning, even in the keyhole welding regime. The proposed LP-FNO maps process parameters to three-dimensional temperature fields and melt-pool boundaries across a broad process window spanning conduction and keyhole regimes using the non-dimensional normalized enthalpy formulation. The model achieves temperature prediction errors on the order of 1% and intersection-over-union scores for melt-pool segmentation over 0.9. We demonstrate that a LP-FNO model trained on coarse-resolution data can be evaluated on finer grids, yielding accurate super-resolved predictions in mesh-converged conduction regimes, whereas discrepancies in keyhole regimes reflect unresolved dynamics in the coarse-mesh training data. These results indicate that the LP-FNO provides an efficient surrogate modeling framework for laser welding, enabling prediction of full three-dimensional fields and phase interfaces over wide parameter ranges in just tens of milliseconds, up to a hundred thousand times faster than traditional Finite Volume multi-physics software.