Search Results (31)

Soft body armor (SBA) remains an essential component of first responder protection. However, most SBA design concepts do not adequately address the unique performance, morphological, and psychological needs of women as first responders. In this review, female-specific designs of ballistic-resistant panels, material systems, and SBA performance testing are critically examined. The paper also explores innovations in shaping and design techniques, including darting, dartless shape construction, modular assembly, and body scanning with CAD integration to create contoured and structurally stable panels with improved coverage, reduced bulk, and greater mobility. In addition, the review addresses broadly used and emerging dry textile fabrics and fiber-reinforced polymers, considering various innovations, such as 3D warp interlock weave, shear thickening fluid (STF) coating, nanomaterials, and smart composites that improve energy dissipation and impact tolerance without sacrificing flexibility. In addition, the paper also examines various emerging ballistic performance testing standards and their revisions to incorporate gender-specific standards and measures their ability to decrease trauma effects and maintain flexibility and practical protection. Finally, it identifies existing challenges and areas of future research, such as optimizing multi-layer systems, addressing fatigue behavior, and improving multi-angle and low-velocity impact performance while providing avenues for future sustainable, adaptive, and performance-optimized body armor. Full article

The armor layer is one of the core components of flexible risers. It provides essential mechanical properties such as tensile strength, pressure resistance, and torsional performance, which are necessary for operation in complex marine environments. However, due to the significant disparity between the cross-sectional dimensions of the armor wires and the overall riser size, severe computational costs are often incurred when a finite element (FE) model is employed for the performance analysis of an armor layer. To address this, an asymptotic homogenization method for flexible risers is established in the present study. In this method, the armor wires, modeled as beam elements, are equivalent to an anisotropic shell structure, and the equivalent elastic properties of the armor layer are obtained with unit-cell analysis. These properties are then used for the overall analysis of the flexible riser’s armor layer response, without considering the specific characteristics of the steel wires, thereby improving the efficiency of the performance analysis. The effectiveness of the proposed method is verified in a numerical example based on a comparison with a finite element (FE) model. Moreover, the effect of the unit cell size is investigated by introducing a size factor. A significant size effect is observed, unlike in the truss-based unit cell, for which an explanation based on the stiffness coefficient is given. The proposed method offers a new technique for efficient performance analysis of the armor layer of flexible risers. Full article

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. Full article

The tensile armor layer plays a crucial role in offshore flexible pipelines, primarily bearing axial tensile loads. However, during installation and operation, it may experience compressive forces, leading to a risk of lateral buckling, which is further intensified by manufacturing deviations in the steel strips. This study introduces a method to quantify these deviations based on the circumferential length change in defect segments in helically wound steel strips. A deviation model is established and analyzed using Abaqus finite element simulations to evaluate the impact of helical angles and deviation severity on the critical lateral buckling load. The results reveal that as the deviation severity increases, the critical buckling load significantly decreases, with reductions of up to 65% for small helical angles. Additionally, the rapid rise in bending moment at the defect location is identified as the primary cause of lateral buckling initiation. Full article

Dynamic stab resistance is a critical property for protective textiles and fibrous composites used in body armor and protective gear applications. This is also a very complex property that depends on various factors, including material properties, structural design, and external impact conditions. This review paper presents an in-depth investigation into the dynamic stab impact response and performance of textile and composite materials, focusing on the influences of various endogenous and exogenous parameters. Material-level factors, including material type and properties, fiber orientation, yarn density, textile architecture, chemical treatments, and coatings, are reviewed. In addition, the influence of external conditions, including impact velocity and energy, blade shape and type, impact condition, and impact angles on the stab resistance of the protective materials are discussed. The interplay of these factors significantly affects penetration resistance, energy absorption, and trauma mitigation. This paper further discusses different stab resistance testing methods and standards on various kinds of protective materials and relatively compared the efficiencies of each. Current challenges on flexibility versus protection and future research directions necessary to realize advances in protective textiles with dynamic stab resistance are debated. The present comprehensive analysis gives useful insights to engineers, manufacturers, researchers, and standard makers for selecting, developing, and testing protective textiles and fibrous composite materials with improved stab protection applications. Full article

Natural armors found in animals like fish and armadillos offer inspiration for designing protective systems that balance puncture resistance and flexibility. Although segmented armors have been used historically, modern applications are hindered by a limited understanding of their mechanics. This study addresses these challenges by presenting two novel bio-inspired scale structures with overlapping and staggered configurations, modeled after the elasmoid designs found in fish. Their shapes differ significantly from other artificial scales commonly described in the literature, which are typically flat. Instead, these scales feature a support that extends vertically from the substrate, transitioning into an inclined surface that serves as the protective component. Finite element method tests evaluated their performance in puncture resistance and flexibility. The results showed that one type of scale provided better puncture resistance, while the other type offered greater flexibility. These findings highlight how small geometric variations can significantly influence the balance between protection and flexibility. The results offer new insights into the mechanisms of natural armor and propose innovative designs for personal protective equipment, such as bulletproof vests, protective gloves, and fireproof systems. The finite element simulations employed to test the protective systems can also serve as valuable tools for the scientific community to assess and refine designs. Full article

The migration of acid gases through the pressure sheath of flexible pipes may induce a corrosive environment that can lead to steel armors’ failure by SCC (stress corrosion cracking). This permeation process depends on temperature, partial pressures, materials, and the pipe’s geometry. However, there are few works related to permeation modeling in flexible pipes, and these works usually contain significant simplification in pipes’ geometry. Hence, this work proposes two finite element (FE) permeation models and discusses the effects of the pipe’s characteristics. The models were developed in Ansys^®, considering two- (2DFE) and three-dimensional (3DFE) approaches, and rely on gas fugacities instead of concentrations to describe the mass transport phenomenon. A radial temperature gradient is also considered, and the heat transfer is uncoupled from the mass transfer. Dry and flooded annulus analyses were conducted with the proposed models. In dry conditions, the results obtained with the 2DFE and the 3DFE approaches showed no significant differences, demonstrating that 3D effects are irrelevant. Hence, the permeation phenomenon is ruled by the permeation properties of the polymeric layers (pressure and outer sheaths) and possible shield effects promoted by the metallic armors. In contrast, the flooded annulus analyses resulted in a non-uniform fugacity distribution in the annulus with significant differences between the 2DFE and the 3DFE approaches, showing the importance of modeling the helical geometries of the metallic armors in this condition. Finally, a conservative 2DFE approach, which neglects the contribution of the pressure sheath, is proposed to analyze the flooded annulus condition, aiming to overcome the high computational cost demanded by the 3DFE approach. Full article

Unbonded flexible risers have been widely used in the field of offshore engineering in recent years due to their excellent performance in extreme dynamic marine environments, structural compliance, low installation cost, and low quality. And, the internal pressure capacity of unbonded flexible risers is an important indicator of the mechanical performance of unbonded flexible risers. Based on a 2.5-inch, 8-layer typical unbonded flexible riser model, this paper examines the burst failure of the pressure armor layer. Firstly, the balance equation of each separate cylindrical layer and helical layer is derived by functional principle, and then the overall theoretical modeling of an unbonded flexible riser under axisymmetric loads is established by additionally considering the geometric relation between adjacent layers. Secondly, fully considering the complex cross-sectional geometric characteristics and the interlayer’s contact with the unbonded flexible riser, a simplified numerical 7-layer model is established by Abaqus, and the material with elastic-plastic properties is conferred. Finally, the validity of the proposed theoretical and numerical methods is verified through the axisymmetric behavior of the test data. Then the burst failure of the pressure armor layer is analyzed based on the material. At an internal pressure of 42 MPa, the pressure armor layer reached its yield stress of 300 MPa, with the entire cross-section yielding between 42 MPa and 42.5 MPa. Additionally, the effect of the friction coefficient is examined. Full article

The application of carbon fiber-reinforced composite materials in marine engineering is growing steadily. The mechanical properties of unbonded flexible risers using composite tensile armor wire are highly valued. However, the curing process generates a certain amount of internal residual stress. We present a detailed analysis of epoxy resin laminates to assess the impact of thermal, chemical, and mechanical effects on the curing stress and strain. An empirical model that correlates temperature and degree of cure was developed to precisely fit the elastic modulus data of the curing resin. The chemical kinetics of the epoxy resin system was characterized using differential scanning calorimetry (DSC), while the tensile relaxation modulus was determined through a dynamic mechanical analysis. The viscoelastic model was calibrated using the elastic modulus data of the cured resin combining temperature and degree of the curing (thermochemical kinetics) responses. Based on the principle of time–temperature superposition, the displacement factor and relaxation behavior of the material were also accurately captured by employing the same principle of time–temperature superposition. Utilizing the empirical model for degree of cure and modulus, we predicted micro-curing-induced strains in cured composite materials, which were then validated with experimental observations. Full article

Unbonded flexible risers consist of several helical and cylindrical layers, which can undergo large bending deformation and can be installed in different configurations to adapt to harsh marine environments; thus, they can be applied to transport oil and gas resources from ultra-deep waters (UDW). Due to their special geometric characteristics, they can ensure sufficient axial tensile stiffness while having small bending stiffness, which can undergo large deflection bending deformation. In recent years, the development of unbonded flexible risers has been moving in an intelligent, integrated direction. This paper presents a review of unbonded flexible risers. Firstly, the form and properties of each interlayer of an unbonded flexible riser are introduced, as well as the corresponding performance and configuration characteristics. In recent years, the development of unbonded flexible risers has been evolving, and the development of machine learning on unbonded flexible risers is discussed. Finally, with emphasis on exploring the design characteristics and working principles, three new types of unbonded flexible risers, an integrated production bundle, an unbonded flexible riser with an anti-H₂S layer, and an unbonded flexible riser with a composite armor layer, are presented. The research results show that: (1) the analytical methods of cross-sectional properties of unbonded flexible risers are solved based on ideal assumptions, and the computational accuracy needs to be improved. (2) Numerical methods have evolved from equivalent simplified models to models that account for detailed geometric properties. (3) Compared with ordinary steel risers, the unbonded flexible riser is more suitable for deep-sea resource development, and the structure of each layer can be designed according to the requirements of the actual environment. Full article

Alumina ceramic is an ideal candidate for armor protection, but it is limited by the difficult molding or machining process. Three-dimensional printing imparts a superior geometric flexibility and shows good potential in the preparation of ceramics for armor protection. In this work, alumina ceramics were manufactured via 3D printing, and the effects of different monomers on the photosensitive slurry and sintered ceramics were investigated. The photosensitive slurries using dipropylene glycol diacrylate (DPGDA) as a monomer displayed the optimal curing performance, with a low viscosity, small volume shrinkage and low critical exposure energy, and each of the above properties was conducive to a good curing performance in 3D printing, making it a suitable formula for 3D-printed ceramic materials. In the 3D-printed ceramics with DPGDA as a monomer, a dense and uniform microstructure was exhibited after sintering. In comparison, the sample with trimethylolpropane triacrylate (TMPTA) showed an anisotropic microstructure with interlayer gaps and a porosity of about 9.8%. Attributed to the dense uniform microstructure, the sample with DPGDA exhibited superior properties, including a relative density of 97.5 ± 0.5%, a Vickers hardness of 19.4 ± 0.8 GPa, a fracture toughness of 2.6 ± 0.27 MPa·m^1/2, a bending strength of 690 ± 54 MPa, and a dynamic strength of 3.7 ± 0.6 GPa at a strain rate of 1200 s⁻¹. Full article

The unbonded flexible riser has been increasingly applied in the ocean engineering industry to transport oil and gas resources from the seabed to offshore platforms. The slippage of helical layers, especially the tensile armor layers of unbonded flexible risers, contribute to the nonlinear hysteresis phenomenon, which is a research hotspot and difficulty. In this paper, on the basis of a typical eight-layer unbonded flexible riser model, the nonlinear slippage of a tensile armor layer and the corresponding nonlinear behavior of an unbonded flexible riser subjected to irregular external loads are studied by numerical modeling with detailed cross-sectional properties of the helical layers, and are verified through a theoretical method considering the coupled effect of the external loads on the unbonded flexible riser. Firstly, the balance equation of each layer considering the effect of external loads is established based on functional principles, and the overall theoretical model of the unbonded flexible riser is set up in consideration of the contact between adjacent layers. Secondly, the numerical modeling of each separate layer within the unbonded flexible riser, including the actual geometry of the carcass and pressure armor layer, is established, and solid elements are applied to all the interlayers, thus simulating the nonlinear contact and friction between and within interlayers. Finally, after verification through test data, the behavior of the unbonded flexible riser under the cyclic axial force, torsion, bending moment, and irregular external and internal pressure is studied. The results show that the tensile armor layer can slip under irregular loads. Additionally, some suggestions related to the analysis of unbonded flexible risers under irregular loads are drawn in the end. Full article

Unbonded flexible risers consist of several helical and cylindrical layers, which can undergo large bending deformation and can be installed to different configurations to adapt to harsh marine environments, and is a key equipment in transporting oil and gas resources from Ultra Deep Waters (UDWs) to offshore platforms. The helical interlayer of an unbonded flexible riser makes the structural behavior difficult to predict. In this paper, the axial tensile behavior and the axial tensile ultimate strength of an unbonded flexible riser are studied based on a typical 2.5-inch eight-layer unbonded flexible riser model, and verified through a theoretical method considering the contact between adjacent layers. First, the balance equation of separate layers is deduced by a functional principle, and then the overall theoretical model of an unbonded flexible riser is established considering the geometric relationship between adjacent layers. Then, the numerical model considering the detailed geometric properties of an unbonded flexible riser is established to simulate the axial tensile behavior. Finally, after being verified through the experimental results, the axial tensile stiffness and axial tensile strength of an unboned flexible riser considering the elasticity of the tensile armor layer are studied using the proposed two methods. Additionally, the effect of frictional coefficients is conducted. The numerical and theoretical results show good agreement with the test results, and the friction between adjacent layers would increase the axial tensile stiffness of an unbonded flexible riser. Full article

The exploitation and harnessing of offshore marine renewable energy have led to an increased demand for reliable marine power cables with long service lives. These cables constitute a considerable share of the total installation cost of offshore renewable energy facilities and have high maintenance and repair costs. The critical characteristics of these power cables must be determined to reduce the risk of exceeding their ultimate strength or fatigue life, which can result in unwanted and unexpected failures. This study investigates dynamic marine power cables that are suitable for application in devices that harness energy from ocean currents, waves, and tides. Tension, bending, torsion, and fatigue tests were conducted on three dynamic power cables (1 kV, 3.6 kV, and 24 kV) that have high flexibility, i.e., low mechanical stiffness. The specimen lengths and axial pretension force were varied during the tests. The results are discussed in terms of the mechanical fatigue degradation and ultimate design load, and the key observations and lessons learned from the tests are clarified. The study’s main contribution is the results from physical component testing of the dynamic marine power cables without metallic armors, which can be used to calibrate numerical models of this type of dynamic marine power cable in the initial design of, e.g., inter-array cables between floating wave energy converters. The benefits offered by this type of cable and the importance of the results for creating reliable numerical simulation models in the future are highlighted. Full article

In this paper, we present a new stress calculation method for flexible structures, particularly, tensile armors, and apply it to flexible riser fatigue analysis. The method is based on a 3-dimensional curved bar theory. First, the tensile armor center line was described as a cylindrical helix curve; its bent curve length and bending migration length were derived and studied under different friction scenarios. Second, the tensile and bending stiffness was derived with consideration of more accurate shape parameters and the frictional hysteretic effect, and verified through FEA analysis results. Third, we presented the stress calculation formula for tensile armor under tension and bending load. All stress components were considered, including tensile, bending and shear stresses. Fourth, the method was benchmarked with published experimental results on a flexible prototype tension and bending tests, and comparisons showed general agreements. Fifth, the method was applied to an in-service 8″ flexible riser for fatigue assessment and lifetime extension evaluation, and showed the flexible riser has sufficient remaining fatigue life, and is suitable to continue its service under the current operating conditions. Last, conclusions were drawn. We concluded that the presented tensile armor stress calculation method and modelling techniques are valid for flexible riser fatigue analysis. This method is time efficient, and can be implemented into other multi-scale models for riser dynamic analysis. It is also applicable to other similar helix structure stress analysis, such as wire ropes, submarine hoses, and subsea umbilicals. Full article