Pre-Rolling Forming-Quality Prediction in 2219 Aluminum Alloy Ring Rolling Using Physics-Informed Heterogeneous Stacking

Industrial 2219 aluminum alloy ring production requires quality assessment before a prescribed rolling plan is executed. At the investigated site, independent geometric inspection is incomplete and forming-quality feedback is not used for in-process plan adjustment. This study establishes a pre-rolling prediction framework by separating quality supervision derived from historical process signals from information available for a new workpiece. A terminal radial-fluctuation root-mean-square (TRF-RMS) indicator is constructed from the follower-roll terminal response and mapped to three enterprise-defined grades. Physics-informed heterogeneous stacking (PI-HStack) predicts these process-based grades using blank and target geometry, derived geometric relationships, initial temperature, and prescribed rolling time. Engineering descriptors represent the planned transformation; out-of-fold probability fusion combines learners, and class-specific decision adjustment addresses three-grade assignment. Five stratified 80/20 hold-out tests on 2224 industrial records yielded mean accuracy of 0.6769, macro-averaged F1-score (Macro-F1) of 0.6436, and macro-averaged one-vs-rest area under the receiver operating characteristic curve (Macro-AUC) of 0.8316. Basic geometry already provides substantial predictive information, and additional descriptors do not improve all objectives. PI-HStack has the highest reported mean overall metrics, whereas extreme gradient boosting (XGBoost) performs better on poor-grade screening measures. Ranking by the PI-HStack poor-grade score captures 56.28% of poor-grade records within the highest-ranked 20% of test records. The findings support objective-specific feature and model selection for pre-rolling plan review. The evaluation is retrospective and limited to the observed production distribution; independent geometric-tolerance validation and generalization to unseen specifications remain unestablished.