Thermo-Mechanical Expansion Behavior of Multilayer Hybrid Composite Materials Under Variable Thermal Loading

Abstract

Multilayer hybrid composite materials are increasingly utilized in aerospace, automotive, marine, and advanced structural engineering applications due to their superior strength-to-weight ratio, thermal resistance, and customizable mechanical properties. However, exposure to variable thermal loading conditions can induce complex thermo-mechanical expansion behavior, interlayer stress development, and structural instability that significantly affect long-term performance and durability. This research presents an investigation of the thermo-mechanical expansion behavior of multilayer hybrid composite materials under variable thermal loading conditions to evaluate deformation characteristics, stress distribution, and thermal stability. The proposed study employs experimental analysis and finite element–based numerical simulation techniques to examine the influence of temperature variation, thermal cycling, material layering sequence, and fiber orientation on composite expansion behavior. The thermo-mechanical response of multilayer hybrid composites is analyzed considering anisotropic material properties, interfacial bonding characteristics, and differential thermal expansion effects between constituent layers. Advanced material characterization techniques are further utilized to evaluate thermal strain behavior, delamination tendencies, and microstructural changes under varying thermal environments. Performance assessment is conducted using parameters such as coefficient of thermal expansion, interlaminar stress distribution, thermal deformation, structural stiffness retention, fatigue resistance, and thermal shock stability. Experimental and simulation results demonstrate that multilayer hybrid composite structures exhibit highly dependent thermo-mechanical behavior based on layer configuration and thermal loading intensity.