A bidirectional zero thermal expansion design method for carbon fiber composite structures

TY - JOUR

T1 - A bidirectional zero thermal expansion design method for carbon fiber composite structures

AU - Li, Huimin

AU - Zhang, Xinlong

AU - Liu, Xin

AU - Teng, Shengpeng

AU - Chen, Xianglin

N1 - Publisher Copyright: © 2026 Elsevier Ltd.

PY - 2026/6/16

Y1 - 2026/6/16

N2 - The invariance of structural dimensions during temperature changes is crucial for high-precision optical platforms, aerospace equipment , and metrological components. The adjustability of the effective coefficient of thermal expansion (CTE) of traditional composite laminates is limited, and the existing concepts of zero thermal expansion (ZTE) are often constrained to one direction or dependent on porous mechanisms that reduce structural stiffness. This work presents a deterministic design method for bidirectional zero thermal expansion composite structures using a single material without introducing flexible hinges. The structure consists of a lower laminate and an upper laminate, forming a thermal-induced bending compensation mechanism. A combined thermal-moment model is established to characterize the coupling between axial strain, in-plane thermal mismatch, and layer-level bending. Analytical expressions for the effective CTE in the both principal directions are derived, enabling the identification of parameter ranges that simultaneously satisfy the ZTE constraints. The optimized design structure is evaluated using three-dimensional finite element simulation, and the predicted CTE is consistent with the theoretical results. In addition, the optimized structure is prepared using hot press molding process, and the bidirectional compensation mechanism is verified by measuring the thermal deformation between 20 °C and 200 °C. The proposed approach provides a fully manufacturable route to achieve bidirectional ZTE composite structures suitable for high thermal stability engineering applications.

AB - The invariance of structural dimensions during temperature changes is crucial for high-precision optical platforms, aerospace equipment , and metrological components. The adjustability of the effective coefficient of thermal expansion (CTE) of traditional composite laminates is limited, and the existing concepts of zero thermal expansion (ZTE) are often constrained to one direction or dependent on porous mechanisms that reduce structural stiffness. This work presents a deterministic design method for bidirectional zero thermal expansion composite structures using a single material without introducing flexible hinges. The structure consists of a lower laminate and an upper laminate, forming a thermal-induced bending compensation mechanism. A combined thermal-moment model is established to characterize the coupling between axial strain, in-plane thermal mismatch, and layer-level bending. Analytical expressions for the effective CTE in the both principal directions are derived, enabling the identification of parameter ranges that simultaneously satisfy the ZTE constraints. The optimized design structure is evaluated using three-dimensional finite element simulation, and the predicted CTE is consistent with the theoretical results. In addition, the optimized structure is prepared using hot press molding process, and the bidirectional compensation mechanism is verified by measuring the thermal deformation between 20 °C and 200 °C. The proposed approach provides a fully manufacturable route to achieve bidirectional ZTE composite structures suitable for high thermal stability engineering applications.

KW - Carbon fiber reinforced polymer

KW - Coefficient of thermal expansion

KW - Composite structures

KW - Design method

KW - Zero thermal expansion

UR - https://www.scopus.com/pages/publications/105033616376

U2 - 10.1016/j.compscitech.2026.111619

DO - 10.1016/j.compscitech.2026.111619

M3 - Article

AN - SCOPUS:105033616376

SN - 0266-3538

VL - 280

JO - Composites Science and Technology

JF - Composites Science and Technology

M1 - 111619

ER -