Acta Metallurgica Sinica (English Letters) ›› 2025, Vol. 38 ›› Issue (8): 1293-1311.DOI: 10.1007/s40195-025-01891-5

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A Review of Intelligent Design and Optimization of Metal Casting Processes

Xiaolong Pei1, Hua Hou1,2, Yuhong Zhao1,3,4()   

  1. 1School of Materials Science and Engineering, Collaborative Innovation Center of Ministry of Education and Shanxi Province for High-Performance Al/Mg Alloy Materials, North University of China, Taiyuan 030051, China
    2School of Materials Science and Engineering, Taiyuan University of Science and Technology, Taiyuan 030024, China
    3Beijing Advanced Innovation Center for Materials Genome Engineering, University of Science and Technology Beijing, Beijing 100083, China
    4Institute of Materials Intelligent Technology, Liaoning Academy of Materials, Shenyang 110004, China
  • Received:2025-02-05 Revised:2025-03-24 Accepted:2025-03-28 Online:2025-08-10 Published:2025-06-24
  • Contact: Yuhong Zhao

Abstract:

Casting technology is a fundamental and irreplaceable method in advanced manufacturing. The design and optimization of casting processes are crucial for producing high-performance, complex metal components. Transitioning from traditional process design based on "experience + experiment" to an integrated, intelligent approach is essential for achieving precise control over microstructure and properties. This paper provides a comprehensive and systematic review of intelligent casting process design and optimization for the first time. First, it explores process design methods based on casting simulation and integrated computational materials engineering (ICME). It then examines the application of machine learning (ML) in process design, highlighting its efficiency and existing challenges, along with the development of integrated intelligent design platforms. Finally, future research directions are discussed to drive further advancements and sustainable development in intelligent casting design and optimization.

Key words: Casting process, Intelligent design, Numerical simulation, Integrated computational materials engineering, Machine learning