Analysis and multi-objective optimization of thermal-hydraulic transport in the transition ladle via response surface method

In twin-roll strip casting, the transition ladle plays a critical role in thermal management and flow stabilization between the tundish and casting rolls, thereby affecting melt distribution uniformity, flow efficiency, and final product quality. This study applies an integrated optimization framework that combines parameter analysis, response surface method, and multi-objective optimization to improve the thermal-hydraulic performance of the melt-delivery system. The outlet temperature difference (Δ T ) and dead volume fraction ( v d ) are adopted as the primary evaluation metrics reflecting distribution uniformity and flow efficiency. Response surface models are constructed based on single-factor analyses to explicitly quantify the influence of geometric parameters on these metrics, after which NSGA-II is employed to simultaneously minimize Δ T and v d . A combined dam-weir flow control device is further introduced to enhance flow regulation, and the optimization procedure is repeated. Results demonstrate that the geometrically optimized structure provides a more uniform initial flow field for subsequent flow control regulation. Furthermore, the optimized design significantly improves distribution uniformity and transport efficiency, providing a more stable condition for subsequent casting stages. Compared with the initial structure, the final design reduces Δ T by 64.86%, the variance of mean residence time among outlets ( Var ) by 99.01%, and v d by 33.75%, while increasing the minimum temperature by 45.97 °C. Subsequent analysis further verifies the robustness of the optimized design.