Hypersonic Flow Control: Generalized Deep Reinforcement Learning for Hypersonic Intake Unstart Control under Uncertainty

The hypersonic unstart phenomenon poses a major challenge to reliable air-breathing propulsion at Mach 5 and above, where strong shock-boundary-layer interactions and rapid pressure fluctuations can destabilize inlet operation. Here, we demonstrate a deep reinforcement learning (DRL)- based active flow control strategy to control unstart in a canonical two-dimensional hypersonic inlet at Mach 5 and Reynolds number 5× 106. The in-house CFD solver enables high-fidelity simulations with adaptive mesh refinement, resolving key flow features, including shock motion, boundary-layer dynamics, and flow separation, that are essential for learning physically consistent control policies suitable for real-time deployment. The DRL controller robustly stabilizes the inlet over a wide range of back pressures representative of varying combustion chamber conditions. It further generalizes to previously unseen scenarios, including different back-pressure levels, Reynolds numbers, and sensor configurations, while operating with noisy measurements, thereby demonstrating strong zero-shot generalization. Control remains robust in the presence of noisy sensor measurements, and a minimal, optimally selected sensor set achieves comparable performance, enabling practical implementation. These results establish a data-driven approach for real-time hypersonic flow control under realistic operational uncertainties.