Study on Interface Design and Functional Tolerance of Structured Composites for Zero Thermal Expansion Performance

Structured zero thermal expansion composites demonstrate significant application potential in thermal deformation control for high-end equipment, particularly aerospace precision instruments, due to their unique ultra-low thermal expansion properties. However, during the transition from theoretical design models to manufacturing models, uncertainties at connection interfaces and manufacturing errors alter the thermal deformation coordination between heterogeneous components within the material, leading to significant degradation of its zero thermal expansion performance. To address this issue, this study focuses on lattice-structured zero thermal expansion composites derived from topology optimization. First, the connection interface design between heterogeneous lattice components was completed. Subsequently, two typical manufacturing errors—dimensional errors and assembly tolerances—were incorporated into the manufacturability model. Using Monte Carlo random sampling, a mapping relationship was established between the random and discrete manufacturing errors and the composite's equivalent thermal expansion performance. Building upon this foundation, a yield rate metric based on functional tolerance concepts was introduced. This metric was used to evaluate how different interface configurations affect the stability of zero thermal expansion performance. The results demonstrate that, under identical manufacturing precision conditions, different interface configurations exhibit significantly varying thermal expansion stability in response to manufacturing errors characterized by structural parameter dispersion. This research provides valuable insights for translating theoretical designs of such functional materials into manufacturable solutions that meet thermal expansion performance requirements.