Optimization and analysis of die-casting Al alloy solid solution process based on response surface model and NSGA-2 algorithm

• Published in: Materials express 2024-02, Vol.14 (2), p.329-338
• Main Authors: Tao, Cheng, Cheng, Xiaonong, Xu, Fuhai, Liu, Guanglei, Li, Zhiqiang, Xie, Shukuan, Kuang, Zhonghua, Guo, Yong, Liu, Haixia
• Format: Article
• Language: English
• Subjects: Algorithms; Aluminum alloys; Aluminum base alloys; Blistering; Die casting; Elongation; Mathematical models; Mechanical properties; Microhardness; Optimization; Process parameters; Response surface methodology; Solid solutions; Solution heat treatment; Tensile strength
• ISSN: 2158-5849; 2158-5857
• DOI: 10.1166/mex.2024.2618

The difficulties of relatively poor overall mechanical characteristics and blistering during heat treatment of the die-cast aluminum alloy are the focus of this study. Using the response surface method, it was determined how temperature and time, two key process factors of solution treatment, interact to affect the microhardness, tensile strength, and elongation of die-cast aluminum alloy. NSGA-2 algorithm was used to optimize the process parameters deeply and accurately. The findings demonstrated that a more accurate model with an error between the predicted and actual value of less than 3% could be created using the combined optimization approach consisting of the response surface method and the NSGA-2 algorithm. The optimal process parameter scheme corresponding to different target results could be obtained rapidly from the model. The casting had a uniform microstructure due to the solid solution treatment with a surface porosity of 0.33%. This can ensure the enhancement of the tensile strength, elongation, and other mechanical properties of the casting, having significant engineering applications.