Accelerating Multiscale Modeling with Hybrid Solvers: Coupling FEM and Neural Operators with Domain Decomposition

Numerical solvers for partial differential equations (PDEs) face challenges balancing computational cost and accuracy, especially in multiscale and dynamic systems. Neural operators can significantly speed up simulations; however, they often face challenges such as error accumulation and limited generalization in multiphysics problems. This work introduces a novel hybrid framework that integrates physics-informed DeepONet with FEM through domain decomposition. The core innovation lies in adaptively coupling FEM and DeepONet subdomains via a Schwarz alternating method. This methodology strategically allocates computationally demanding regions to a pre-trained Deep Operator Network, while the remaining computational domain is solved through FEM. To address dynamic systems, we integrate the Newmark time-stepping scheme directly into the DeepONet, significantly mitigating error accumulation in long-term simulations. Furthermore, an adaptive subdomain evolution enables the ML-resolved region to expand dynamically, capturing emerging fine-scale features without remeshing. The framework's efficacy has been validated across a range of solid mechanics problems, including static, quasi-static, and dynamic regimes, demonstrating accelerated convergence rates (up to 20% improvement compared to FE-FE approaches), while preserving solution fidelity with error < 1%. Our case studies show that our proposed hybrid solver: (1) maintains solution continuity across subdomain interfaces, (2) reduces computational costs by eliminating fine mesh requirements, (3) mitigates error accumulation in time-dependent simulations, and (4) enables automatic adaptation to evolving physical phenomena. This work bridges the gap between numerical methods and AI-driven surrogates, offering a scalable pathway for high-fidelity simulations in engineering and scientific applications.