With the increasing thrust-to-weight ratio of modern aeroengines and the widespread adoption of thin-walled casing, the impact of the coupling vibration effect between the rotor and stator on the critical speed, rotor–stator mode shape coordination, and response characteristics of the whole engine have become increasingly prominent. However, the vibrational design of the whole-engine coupling has thus far relied on human experience, revealing a need for the study of its intelligent optimization. In this study, to quantitatively analyze the vibration of the whole engine, three vibration evaluation indexes were defined, which were risk coefficients for the critical speed, rotor strain energy, and cross-section rotor–stator rubbing. Using these indexes as the optimization targets, a multi-objective intelligent optimization design method for aeroengine support stiffness was proposed. The design optimization of the support stiffness of a turbofan engine with a large bypass ratio was performed. The results showed that the vibration index of the whole machine can be reduced to different degrees and that the whole-engine coupling vibration is optimized.

This study addresses the critical challenges of interfacial stress mismatch, fiber degradation, and unstable clad geometry in manufacturing continuous carbon fiber-reinforced aluminum composites (Cf/Al) via laser cladding, driven by rapid thermal gradients. A dual-ellipsoid heat source-based thermoelastic–plastic finite element model was developed in Abaqus, integrating phase-dependent material properties and latent heat effects to simulate multi-physics interactions during single-track deposition, resolving transient temperature fields peaking at 1265 °C, and residual stresses across uncoated and Ni-coated fiber configurations. The work identifies an optimal parameter window characterized by laser power ranging from 700 to 800 W, scan speed of 2 mm/s, and spot radius of 3 mm that minimizes thermal distortion below 5% through gradient-controlled energy delivery, while quantitatively demonstrating nickel interlayers’ dual protective role in achieving 42% reduction in fiber degradation at 1200 °C compared to uncoated systems and enhancing interfacial load transfer efficiency by 34.7%, thereby reducing matrix tensile stresses to 159 MPa at fiber interfaces. Experimental validation confirms the model’s predictive capability, revealing nickel-coated systems exhibit superior thermal stability with temperature differentials below 12.6 °C across interfaces and mechanical interlocking, achieving interfacial void fractions under 8%. These results establish a process–structure linkage framework, advancing defect-controlled composite fabrication and providing a digital twin methodology for aerospace-grade manufacturing.