Flexible pipes are extensively used to connect seabed and floating production systems for the development of deep-water oil and gas. In the top connection area, end fitting (EF) is the connector between the flexible pipe and floating platform, as a critical component for structural failure. To address this issue, a combined numerical and experimental prediction method is proposed in this paper to investigate the failure behavior of flexible pipes EF considering tensile armor and epoxy resin debonding. In order to analyze the stress distribution of the tensile armor and the damage state of the bonding interface as the tensile load increases, a finite element model of the EF anchorage system is established based on the cohesive zone model (CZM). Additionally, the effects of the epoxy resin shear strength (ss) and the steel wire yield strength (ys) on the structural load-bearing capacity are discussed in detail. The results indicate that wire strength and interface bonding have a substantial effect on the anchorage system’s failure behavior, and the low-strength wire anchorage system has a three-stage failure behavior with wire yielding as the predominant failure mode, while the high-strength wire anchorage system has a two-stage failure behavior with interface debonding as the predominant failure mode.

Current designs of sealing systems for non-adhesive flexible pipe end-fittings primarily address short-term loading conditions, often overlooking the creep behavior of polyvinylidene fluoride (PVDF) and the material used in the sealing layer. Over time, the creep of PVDF, particularly at elevated temperatures, can lead to excessive reduction in the sealing layer’s thickness, thereby compromising the sealing performance of the end-fittings. In this study, to address the creep-related issues in the sealing layer, the compression and compression creep tests of PVDF were conducted at different temperatures to establish the material’s elastic-plastic constitutive relationship and develop a creep constitutive model based on the time hardening model. Using the pressure penetration method within ABAQUS software, a two-dimensional axisymmetric finite element model of the end-fitting sealing system was constructed, incorporating the effects of internal fluid pressure. This model was employed to analyze the sealing performance while accounting for the materials’ creep behavior across varying temperature conditions. The results demonstrate that creep in the sealing layer occurs predominantly in the early stages post-installation. Furthermore, the API 17J standard, which stipulates that reduction in sealing layer thickness should not exceed 30%, is found to be conservative at high temperatures. In these conditions, although the thickness reduction exceeds 30% before the maximum contact pressure drops below the fluid pressure, no fluid leakage is observed. Thus, in the initial phase following installation, especially at elevated temperatures, monitoring for potential leakage is critical. This research is the first to quantify the long-term impact of PVDF creep behavior on the sealing performance of flexible pipe end-fittings through comprehensive experiments and simulation analysis. The findings provide both a theoretical foundation and practical guidance for enhancing the long-term sealing performance of flexible pipe end-fittings.

A cryogenic hose is used to transport liquefied natural gas at sea, where flexible fittings are sealed by corrugated lining and end flange welding. However, the extreme cryogenic temperatures of the conveyed fluid introduce substantial challenges to the integrity of the fitting seals’ structure during the LNG transfer process. In order to study the sealing performance of the fitting under LNG conveying conditions, this paper was based on the general finite element software ABAQUS 6.11 to carry out a thermo-mechanical coupling analysis of the end sealing stress. This paper also established a sealing performance analysis model of the corrugated fitting welding area under the fitting action of LNG load and internal pressure load. A sensitivity analysis was conducted on the influence of weld clearance, blunt edge size, and weld residual height on the weld stress of a fitting ring. The results show that, under the combined action of the medium internal pressure and cryogenic load, the size design of the weld area significantly affects the sealing performance of the fitting, among which the equivalent force of the weld clearance butt sealing area has the greatest impact. Moreover, it was found that a pressure of 5 MPa was 2 mm when the weld clearance was 2 mm, and the average stress at the weld was 53.68 MPa. Further, considering the synergistic influence of the blunt edge size, the weld clearance was 3 mm, the stress was minimal when the blunt side size was 4 mm, and the average stress was 17.42 MPa. These research results can serve as a reference for the design and analysis of the sealing structure of non-adhesive inner corrugated cryogenic hose fittings.

The pouring quality of epoxy resin in the resin cavity of deep-water composite flexible pipe end fittings has a decisive effect on the performance of the end fitting, and accurate investigation of the resin flow during the pouring process can provide a reference for optimization of the pouring process so that the pouring quality can be improved. In this paper, numerical methods were employed to investigate the pouring process of the resin cavity. The distribution and evolution of defects were studied, and the influence of pouring rate and fluid viscosity on pouring quality was analyzed. In addition, based on the simulation results obtained, some local pouring simulations were conducted for the armor steel wire, the key characteristic structure of the end fitting resin cavity that has a significant influence on the pouring quality, to investigate the influence of the geometrical characteristics of the armor steel wire on the pouring quality. Based on these results, the existing end fitting resin cavity structure and pouring process were optimized, and better pouring quality was obtained.

Flexible pipe end fittings (EFs) transfer axial loads by embedding tensile armor within epoxy matrices. The integrity of bonding between the armor and resin profoundly influences the EF load-bearing capacity. This study investigated the debonding failure mechanism at the epoxy-resin–tensile-armor interface in flexible pipe end fittings through integrated experimental and numerical approaches. Combining tensile tests with digital image correlation (DIC) and cohesive zone modeling (CZM), the research quantified the impacts of interfacial defects and adhesive properties on structural integrity. Specimens with varying bond lengths (40–60 mm) and defect diameters (0–4 mm) revealed that defects significantly reduced load-bearing capacity, with larger defects exacerbating strain localization and accelerating failure. A dimensionless parameter, the defect-size-to-bond-length ratio ($\lambda =D/2L$), was proposed to unify defect impact analysis, demonstrating its nonlinear relationship with failure load reduction. High-toughness adhesives, such as Sikaforce^® 7752, mitigated defect sensitivity by redistributing stress concentrations, outperforming brittle alternatives like Araldite^® AV138. DIC captured real-time strain evolution and crack propagation, validating strain concentrations up to 3.2 at defect edges, while CZM simulations achieved high accuracy (errors: 3.0–7.2%) in predicting failure loads. Critical thresholds for λ (λ < 0.025 for negligible impact; λ > 0.05 requiring defect control or high-toughness adhesives) were established, providing actionable guidelines for manufacturing optimization and adhesive selection. By bridging experimental dynamics with predictive modeling, this work advances the design of robust deepwater energy infrastructure through defect management and material innovation, offering practical strategies to enhance structural reliability in critical applications.