Flaky POLAR_MATRICES forwarddiff test on Windows / Julia 1.12 (knot-proximity in piecewise-linear polar interpolation)

[ufechner7]

Symptom

The AutoForwardDiff matches AutoFiniteDiff (LOOP, POLAR_MATRICES) testset in test/solver/test_forwarddiff.jl fails on Windows and on Ubuntu with Julia 1.12, but passes on Ubuntu with Julia 1.13:

┌ Info: POLAR_MATRICES jacobian norms
│   norm_fwd = 3.2830924234545438
└   norm_fd = 3.2851809771070055
AutoForwardDiff matches AutoFiniteDiff (LOOP, POLAR_MATRICES): Test Failed at D:\a\VortexStepMethod.jl\VortexStepMethod.jl\test\solver\test_forwarddiff.jl:87
  Expression: relative_error(jac_fd, jac_fwd) < 0.0001
   Evaluated: 0.04771407501932747 < 0.0001

Diagnosis

This is a recurrence of a failure mode that has already been hit and patched twice:

• 320e7565 — "Make the POLAR_MATRICES forwarddiff check robust on Windows" (widened the tolerance)
• ae11d48d — "Make polar generation deterministic so the forwarddiff test stops flaking on Windows" (pinned BLAS.set_num_threads(1) during NeuralFoil table generation, since matmuls are only bit-reproducible single-threaded)
• 5a1d5206 — "Keep the finite-difference reference off the polar's alpha knots" (tightened rtol to 1e-11 and the FD step to 1e-8, and the assertion back down to 1e-4) — this is the version now failing again on Windows/1.12.

Root cause: the POLAR_MATRICES aerodynamic model interpolates cl/cd/cm with Interpolations.jl's linear_interpolation over a 5°-spaced alpha grid (src/panel.jl, build_interps, calculate_cl/cd/cm) — piecewise-linear, i.e. continuous but not differentiable at each grid knot.

For the operating point used in the test (aoa_rad = deg2rad(7.5) on the ram_air_matrix_wing from test/test_data_utils.jl, grid alpha_range=deg2rad.(-5:5:15)), the LOOP solver converges at least one panel's local angle of attack to a value extremely close (empirically within ~3e-4° in the 5a1d5206 analysis) to one of the 5°/10° knots. Whether the converged value lands just above or just below that knot depends on ~1-ulp differences accumulated through sin/cos/BLAS rounding during the fixed-point LOOP solve — and those differ between platforms (Linux vs Windows libm) and Julia versions (1.12 vs 1.13's bundled math libraries). When AutoForwardDiff (dual numbers through the interpolation) and the finite-difference secant land on opposite sides of the kink, they measure two different (both locally valid) slopes of the piecewise-linear surface, producing the ~4.8% spurious mismatch seen above — not a bug in linearize(), AutoForwardDiff, or AutoFiniteDiff.

Each previous fix re-tuned constants (BLAS threading, solver rtol, FD step, assertion tolerance) against whichever platform was failing at the time, rather than removing the structural cause: the test's operating point/grid combination reliably parks a panel right at a non-differentiable point, so the test's outcome is inherently a coin flip along ~1-ulp platform differences.

Suggested direction (not yet implemented — needs Windows/Julia-1.12 to verify)

Move the interpolation grid's knots away from wherever the wing's real per-panel operating alphas cluster (e.g. offset alpha_range/delta_range in the ram_air_matrix_wing call by a non-round amount, or otherwise verify no panel's converged alpha sits near a knot), rather than continuing to tighten rtol/FD-step/tolerance, which has already been tried twice and hasn't held.

I don't have access to Windows or Julia 1.12 CI to verify a fix locally (this session is Linux/Julia 1.12.7 with a stale local dev Manifest, and even a locally-reproduced Julia 1.12 run wouldn't reproduce the Windows libm path), so a fix needs to be validated against actual CI runs on both flaky platforms.

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🤖 Generated with Claude Code

[ufechner7]

Fixed on main

[1-Bort-1]

Failing again on Windows / Julia 1.12 in #372's CI: AutoForwardDiff matches AutoFiniteDiff (LOOP, POLAR_MATRICES) at test/solver/test_forwarddiff.jl:99, 0.057102607132145794 < 0.0001 (https://github.com/OpenSourceAWE/VortexStepMethod.jl/actions/runs/35653997846/job/106512975869). #372 touches neither the solver nor the test; the other four matrix cells pass.