Response surface methodology is used to construct approximations to temperature and stress in transient thermoelastic analysis of non-linear systems. The analysis forms the core component of a heating/cooling rate maximization problem in which the ordinates of the ambient temperature at equally spaced time intervals are chosen as the design variables. Polynomials or cubic splines are fitted through the ordinates to describe the ambient temperature profile required for the convective heat transfer analysis. An experimental design method based on D-optimality and a genetic algorithm was used to select the design points used to create the approximations. Linear response surfaces were found to be sufficiently accurate, thereby minimizing the number of finite element analyses. Two examples of which one is a thick-walled pressure vessel are used to illustrate the methodology. © 1998 John Wiley & Sons, Ltd.