Refuse a boundary-condition patch geometry the dimensionality never applies

examples/2D_bc_patch_geometry/README.md

@@ -0,0 +1,44 @@
+# Boundary-condition patch geometry has to match the dimensionality
+
+`s_apply_boundary_patches` (`src/pre_process/m_boundary_conditions.fpp`) dispatches by dimensionality:
+
+```fortran
+if (p > 0) then                                  ! 3D
+    if      (patch_bc(i)%geometry == 2) call s_circle_bc(i, bc_type)
+    else if (patch_bc(i)%geometry == 3) call s_rectangle_bc(i, bc_type)
+else if (n > 0) then                             ! 2D
+    if      (patch_bc(i)%geometry == 1) call s_line_segment_bc(i, bc_type)
+```
+
+There is no `else`. A geometry belonging to the other dimensionality falls straight through: **the patch is
+never applied, nothing is printed, and the face silently keeps whatever `bc_[xyz]` gave it.**
+
+That is quiet in the worst way. A nozzle cut into a no-slip wall with a 3D geometry in a 2D case simply stays
+a solid wall — the run completes, writes output, and the jet has a velocity of exactly zero for all time with
+no indication anything was ignored.
+
+## Running it
+
+```
+./mfc.sh validate examples/2D_bc_patch_geometry/case.py                  # geometry 1, valid in 2D
+GEOMETRY=3 ./mfc.sh validate examples/2D_bc_patch_geometry/case.py       # a 3D geometry in a 2D case
+```
+
+| | before | after |
+| --- | --- | --- |
+| `GEOMETRY=1` | passes | passes |
+| `GEOMETRY=3` | **passes, then does nothing at run time** | `patch_bc(1)%geometry must be 1 (line segment) in 2D; geometry 3 is never applied` |
+
+The 3D direction is symmetric: geometry 1 in a 3D case is equally ignored, and is now equally refused.
+
+## A second trap in the same corner
+
+The case carries a second initial-condition patch a few cells thick at the inlet, and it is load-bearing:
+the Dirichlet buffer is filled by pre_process from the **initial condition at the boundary face**. A domain
+initialised at rest stores rest in that buffer, and the "inflow" then delivers zero for all time — again with
+no warning. This is not what the validator change addresses; it is noted here because the two failures look
+identical from the outside, and knowing that saves working out which one is in play.
+
+## Scope
+
+Validator only; no source change and no golden files. All 182 example cases still validate.

examples/2D_bc_patch_geometry/case.py

@@ -0,0 +1,99 @@
+#!/usr/bin/env python3
+"""A 2D boundary-condition patch, with the geometry the dimensionality actually supports.
+
+`s_apply_boundary_patches` dispatches by dimensionality: geometry 1 (line segment) in 2D, geometry 2 (circle)
+or 3 (rectangle) in 3D. A geometry belonging to the other case falls straight through the dispatch -- the
+patch is never applied, and the face silently keeps whatever `bc_[xyz]` gave it.
+
+Set GEOMETRY=3 to see the validator refuse what used to pass quietly:
+
+    python3 case.py                 # geometry 1, valid in 2D
+    GEOMETRY=3 python3 case.py      # a 3D geometry in a 2D case
+"""
+
+import json
+import os
+
+gamma, rho, U, Ma = 1.4, 1.0, 1.0, 0.6
+cs = U / Ma
+P = rho * cs**2 / gamma
+D, L, H = 1.0, 8.0, 6.0
+dx = D / 20
+N, NY = int(L / dx), int(H / dx)
+
+case = {
+    "run_time_info": "T",
+    "parallel_io": "T",
+    "prim_vars_wrt": "T",
+    "format": "silo",
+    "precision": "double",
+    "x_domain%beg": 0.0,
+    "x_domain%end": L,
+    "y_domain%beg": -0.5 * H,
+    "y_domain%end": 0.5 * H,
+    "m": N - 1,
+    "n": NY - 1,
+    "p": 0,
+    "cyl_coord": "F",
+    "dt": 0.2 * dx / (U + cs),
+    "t_step_start": 0,
+    "t_step_stop": 100,
+    "t_step_save": 100,
+    "num_patches": 2,
+    "num_fluids": 1,
+    "model_eqns": "5eq",
+    "alt_soundspeed": "F",
+    "mpp_lim": "F",
+    "mixture_err": "T",
+    "time_stepper": "rk3",
+    "weno_order": 5,
+    "weno_eps": 1.0e-10,
+    "weno_avg": "T",
+    "avg_state": "arithmetic",
+    "mapped_weno": "T",
+    "null_weights": "F",
+    "mp_weno": "F",
+    "riemann_solver": "hllc",
+    "low_Mach": 2,
+    "wave_speeds": "direct",
+    "viscous": "F",
+    "fd_order": 4,
+    "patch_icpp(1)%geometry": 3,
+    "patch_icpp(1)%x_centroid": 0.5 * L,
+    "patch_icpp(1)%y_centroid": 0.0,
+    "patch_icpp(1)%length_x": L,
+    "patch_icpp(1)%length_y": H,
+    "patch_icpp(1)%vel(1)": 0.0,
+    "patch_icpp(1)%vel(2)": 0.0,
+    "patch_icpp(1)%pres": P,
+    "patch_icpp(1)%alpha_rho(1)": rho,
+    "patch_icpp(1)%alpha(1)": 1.0,
+    # The Dirichlet buffer is filled by pre_process from the initial condition *at the boundary face*, so the
+    # inflow state has to be present there. A face initialised at rest stores rest and delivers nothing.
+    "patch_icpp(2)%geometry": 3,
+    "patch_icpp(2)%alter_patch(1)": "T",
+    "patch_icpp(2)%x_centroid": 2 * dx,
+    "patch_icpp(2)%y_centroid": 0.0,
+    "patch_icpp(2)%length_x": 4 * dx,
+    "patch_icpp(2)%length_y": D,
+    "patch_icpp(2)%vel(1)": U,
+    "patch_icpp(2)%vel(2)": 0.0,
+    "patch_icpp(2)%pres": P,
+    "patch_icpp(2)%alpha_rho(1)": rho,
+    "patch_icpp(2)%alpha(1)": 1.0,
+    "fluid_pp(1)%gamma": 1.0 / (gamma - 1.0),
+    "fluid_pp(1)%eos": "ideal_gas",
+    # a wall with a nozzle cut into it
+    "bc_x%beg": -16,
+    "num_bc_patches": 1,
+    "patch_bc(1)%dir": 1,
+    "patch_bc(1)%loc": -1,
+    "patch_bc(1)%type": -17,
+    "patch_bc(1)%geometry": int(os.environ.get("GEOMETRY", 1)),
+    "patch_bc(1)%centroid(2)": 0.0,
+    "patch_bc(1)%length(2)": D,
+    "bc_x%end": -8,
+    "bc_y%beg": -8,
+    "bc_y%end": -8,
+}
+print(json.dumps(case, indent=4))

toolchain/mfc/case_validator.py

@@ -2217,6 +2217,20 @@ def check_bc_patches(self):
             if geometry is None:
                 continue
 
+            # s_apply_boundary_patches dispatches by dimensionality: geometry 1 in 2D, 2 or 3 in 3D. A
+            # geometry that belongs to the other case falls through the dispatch, the patch is never applied,
+            # and the face silently keeps whatever bc_[xyz] gave it -- a nozzle cut into a wall simply stays a
+            # wall, with no warning and a jet that never starts.
+            p = self.get("p", 0) or 0
+            n = self.get("n", 0) or 0
+            if p > 0:
+                self.prohibit(geometry not in (2, 3), f"patch_bc({i})%geometry must be 2 (circle) or 3 (rectangle) in 3D; " f"geometry {geometry} is never applied")
+            elif n > 0:
+                self.prohibit(geometry != 1, f"patch_bc({i})%geometry must be 1 (line segment) in 2D; " f"geometry {geometry} is never applied")
+            else:
+                # 1D enters neither branch of the dispatch, so every geometry is ignored, not just a mismatched one.
+                self.prohibit(True, f"patch_bc({i})%geometry cannot be used in 1D; boundary-condition patches are only applied in 2D and 3D")
+
             # Line Segment BC (geometry = 1)
             if geometry == 1:
                 self.prohibit(radius is not None, f"Line Segment Patch {i} can't have radius defined")