Hybrid Optimization Approaches for Impeller Design in Turbomachinery: Methods, Metrics, and Design Strategies

Optimizing the design of impellers in turbomachinery is crucial for improving its energy efficiency, structural integrity, and hydraulic performance in various engineering applications. This work proposes a novel modular framework for impeller optimization that integrates high-fidelity CFD and FEM simulations, AI-based surrogate modeling, and multi-objective evolutionary algorithms. A comprehensive analysis of over one hundred recent studies was conducted, with a focus on advanced computational and hybrid optimization techniques, CFD, FEM, surrogate modeling, evolutionary algorithms, and machine learning approaches. Emphasis is placed on multi-objective and data-driven strategies that integrate high-fidelity simulations with metamodels and experimental validation. The findings demonstrate that hybrid methodologies such as combining response surface methodology (RSM), Box–Behnken design (BBD), non-dominated sorting genetic algorithm II (NSGA-II), and XGBoost lead to significant improvements in hydraulic efficiency (up to 6.7%), mass reduction (over 30%), and cavitation mitigation. This study introduces a modular decision-making framework for impeller optimization which considers design objectives, simulation constraints, and the physical characteristics of turbomachinery. Furthermore, emerging trends in open-source tools, additive manufacturing, and the application of deep neural networks are discussed as key enablers for future advancements in both research and industrial applications. This work provides a practical, results-oriented framework for engineers and researchers seeking to enhance the design of impellers in the next generation of turbomachinery.