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<p>This study presents a rigorously validated multi-objective hybrid genetic algorithm (HGA) framework to simultaneously optimize three critical processing parameters, silane coupling agent content (wt.%), (3-aminopropyl) triethoxysilane (APTES) concentration (vol.%), and mechanical stirring speed (rpm), for the fabrication of aluminum powder-reinforced epoxy (Al/EP) particulate composites. The experimental dataset, derived from cast-molded composites incorporating silane-treated and untreated aluminum powder (44&#xa0;μm, 99.5% purity), revealed a statistically significant 240% improvement in ultimate tensile strength (UTS), relative to the untreated Al/epoxy composite baseline, upon APTES silanization (from 6.55 ± 0.58&#xa0;MPa to 22.30 ± 0.71&#xa0;MPa), while Shore D hardness remained statistically equivalent (72-73), confirming that surface chemistry governs interfacial load transfer rather than bulk matrix properties. The HGA, implemented within the NSGA-II framework and augmented with Nelder–Mead local search and Gaussian mutation operators, converged within 200 generations to predict globally optimal conditions of 5.0&#xa0;wt.% silane content, 4.0&#xa0;vol.% APTES, and 175&#xa0;rpm stirring speed. Pareto front analysis comprising 30 non-dominated solutions identified the design point achieving 22.3&#xa0;MPa UTS and 76 Shore D hardness as the preferred Pareto-optimal knee solution. Response surface methodology (RSM), employing Kriging surrogate models trained on 50 experimental and 200 RSM-generated design points, confirmed the dominant effects of APTES concentration and silane content, with Sobol first-order sensitivity indices of 0.42 and 0.35, respectively. Scanning electron microscopy (SEM) fracture surface analysis validated the mechanistic transition from adhesive interfacial debonding in untreated composites to ductile matrix deformation in optimized specimens. X-ray diffraction (XRD) and Fourier-transform infrared (FTIR) spectroscopy confirmed that APTES surface modification preserved the face-centered cubic (FCC) crystalline structure of aluminum while forming stable covalent Si-O-Al bonds, as evidenced by characteristic absorption bands at 1000-1100&#xa0;cm⁻<sup>1</sup>. The proposed HGA framework offers a computationally efficient, transferable methodology for composite manufacturing parameter optimization and demonstrates measurable advantages over conventional one-variable-at-a-time and standard RSM approaches.</p>

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Process Optimization and APTES-Based Interfacial Engineering of Aluminum/Epoxy Particulate Composites for Enhanced Mechanical Performance

  • 期刊论文

  • 发表日期：

    2026年8月4日

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  • C. Surya Kumari,
  • Ajith Raj Rajendran,
  • Muhammed Anaz Khan

摘要

This study presents a rigorously validated multi-objective hybrid genetic algorithm (HGA) framework to simultaneously optimize three critical processing parameters, silane coupling agent content (wt.%), (3-aminopropyl) triethoxysilane (APTES) concentration (vol.%), and mechanical stirring speed (rpm), for the fabrication of aluminum powder-reinforced epoxy (Al/EP) particulate composites. The experimental dataset, derived from cast-molded composites incorporating silane-treated and untreated aluminum powder (44 μm, 99.5% purity), revealed a statistically significant 240% improvement in ultimate tensile strength (UTS), relative to the untreated Al/epoxy composite baseline, upon APTES silanization (from 6.55 ± 0.58 MPa to 22.30 ± 0.71 MPa), while Shore D hardness remained statistically equivalent (72-73), confirming that surface chemistry governs interfacial load transfer rather than bulk matrix properties. The HGA, implemented within the NSGA-II framework and augmented with Nelder–Mead local search and Gaussian mutation operators, converged within 200 generations to predict globally optimal conditions of 5.0 wt.% silane content, 4.0 vol.% APTES, and 175 rpm stirring speed. Pareto front analysis comprising 30 non-dominated solutions identified the design point achieving 22.3 MPa UTS and 76 Shore D hardness as the preferred Pareto-optimal knee solution. Response surface methodology (RSM), employing Kriging surrogate models trained on 50 experimental and 200 RSM-generated design points, confirmed the dominant effects of APTES concentration and silane content, with Sobol first-order sensitivity indices of 0.42 and 0.35, respectively. Scanning electron microscopy (SEM) fracture surface analysis validated the mechanistic transition from adhesive interfacial debonding in untreated composites to ductile matrix deformation in optimized specimens. X-ray diffraction (XRD) and Fourier-transform infrared (FTIR) spectroscopy confirmed that APTES surface modification preserved the face-centered cubic (FCC) crystalline structure of aluminum while forming stable covalent Si-O-Al bonds, as evidenced by characteristic absorption bands at 1000-1100 cm⁻1. The proposed HGA framework offers a computationally efficient, transferable methodology for composite manufacturing parameter optimization and demonstrates measurable advantages over conventional one-variable-at-a-time and standard RSM approaches.