ASTM E2982-14e1

4.1 The COPVs covered in this guide consist of a metallic liner overwrapped with high-strength fibers embedded in polymeric matrix resin (typically a thermoset). Metallic liners may be spun formed from a deep drawn/extruded monolithic blank or may be fabricated by welding formed components. Designers often seek to minimize the liner thickness in the interest of weight reduction. COPV liner materials used can be aluminum alloys, titanium alloys, nickel-chromium alloys, and stainless steels, impermeable polymer liner such as high density polyethylene, or integrated composite materials. Fiber materials can be carbon, aramid, glass, PBO, metals, or hybrids (two or more types of fiber). Matrix resins include epoxies, cyanate esters, polyurethanes, phenolic resins, polyimides (including bismaleimides), polyamides and other high performance polymers. Common bond line adhesives are; FM-73, urethane, West 105, Epon 862 with thicknesses ranging from 0.13 mm (0.005 in.) to 0.38 mm (0.015 in.). Metal liner and composite overwrap materials requirements are found in ANSI/AIAA S-080 and ANSI/AIAA S-081, respectively. Pictures of representative COPVs are shown in E07’s forthcoming Guide for Nondestructive Testing of Composite Overwraps in Filament-Wound Pressure Vessels Used in Aerospace Applications.

4.2 The operative failure modes COPV metal liners and metal PVs, in approximate order of likelihood, are: Note 2: For launch vehicles and satellites, the strong drive to reduce weight has pushed designers to adopt COPVs with thinner metal liners. Unfortunately, this configuration is more susceptible to liner buckling. So, as a precursor to liner fatigue, attention should be paid to liner buckling.

4.3 Per MIL-HDBK-340, the primary intended function of COPVs as discussed in this guide will be to store pressurized gases and fluids where one or more of the following apply:

4.4 Per NASA-STD-(I)-5019, COPVs shall comply with the latest revision of ANSI/AIAA Standard S-081. The following requirements also apply when implementing S-081:

4.5 Application of the NDT procedures discussed in this standard is intended to reduce the likelihood of liner failure, commonly denoted leak before burst (LBB), characterized by leakage and loss of the pressurized commodity, thus mitigating or eliminating the attendant risks associated with loss of the pressurized commodity, and possibly mission.

4.6 Discontinuity Types—Specific discontinuity types are associated with the particular processing, fabrication and service history of the COPV. COPV composite overwraps can have a myriad of possible discontinuity types; with varying degrees of importance in terms of effect on performance (see Section 4.6 in E07’s forthcoming Guide for Nondestructive Testing of Composite Overwraps in Filament-Wound Pressure Vessels Used in Aerospace Applications). As for discontinuities in the metallic liner, the primary concern from an NDT perspective is to detect discontinuities that can develop cracks or reduce residual strength of the liner below the levels required, within the context of the life cycle. Therefore, discontinuities shall be categorized as follows:

4.11 Probability of Detection (POD)—Detailed instruction for assessing the reliability of NDT data using POD of a complex structure such as a COPV is beyond the scope of this guide. Therefore, only general guidance is provided. More detailed instruction for assessing the capability of an NDT procedure in terms of the POD as a function of flaw size, a, can be found in MIL-HDBK-1823. The statistical precision of the estimated POD(a) function (Fig. 1) depends on the number of examination sites with targets, the size of the targets at the examination sites, and the basic nature of the examination result (hit/miss or magnitude of signal response).

4.13 Further Guidance—Additional guidance for fracture control is provided in other governmental documents (NASA-STD-5003, SSP 30558, SSP 52005, NSTS 1700.7B), and non-government documents (NTIAC-DB-97-02, NTIAC-TA-00-01).

1.1 This guide discusses current and potential nondestructive testing (NDT) procedures for finding indications of discontinuities in thin-walled metallic liners in filament-wound pressure vessels, also known as composite overwrapped pressure vessels (COPVs). In general, these vessels have metallic liner thicknesses less than 2.3 mm (0.090 in.), and fiber loadings in the composite overwrap greater than 60 percent by weight. In COPVs, the composite overwrap thickness will be of the order of 2.0 mm (0.080 in.) for smaller vessels, and up to 20 mm (0.80 in.) for larger ones.

1.2 This guide focuses on COPVs with nonload sharing metallic liners used at ambient temperature, which most closely represents a Compressed Gas Association (CGA) Type III metal-lined COPV. However, it also has relevance to (1) monolithic metallic pressure vessels (PVs) (CGA Type I), and (2) metal-lined hoop-wrapped COPVs (CGA Type II).

1.3 The vessels covered by this guide are used in aerospace applications; therefore, the examination requirements for discontinuities and inspection points will in general be different and more stringent than for vessels used in non-aerospace applications.

1.4 This guide applies to (1) low pressure COPVs and PVs used for storing aerospace media at maximum allowable working pressures (MAWPs) up to 3.5 MPa (500 psia) and volumes up to 2 m³ (70 ft³), and (2) high pressure COPVs used for storing compressed gases at MAWPs up to 70 MPa (10,000 psia) and volumes down to 8000 cm³ (500 in.³). Internal vacuum storage or exposure is not considered appropriate for any vessel size.

1.5 The metallic liners under consideration include but are not limited to ones made from aluminum alloys, titanium alloys, nickel-based alloys, and stainless steels. In the case of COPVs, the composites through which the NDT interrogation must be made after overwrapping include, but are not limited to, various polymer matrix resins (for example, epoxies, cyanate esters, polyurethanes, phenolic resins, polyimides (including bismaleimides), polyamides) with continuous fiber reinforcement (for example, carbon, aramid, glass, or poly-(phenylenebenzobisoxazole) (PBO)).

1.6 This guide describes the application of established NDT procedures; namely, Acoustic Emission (AE, Section 7), Eddy Current Testing (ECT, Section 8), Laser Profilometry (LP, Section 9), Leak Testing (LT, Section 10), Penetrant Testing (PT, Section 11), and Radiologic Testing (RT, Section 12). These procedures can be used by cognizant engineering organizations for detecting and evaluating flaws, defects, and accumulated damage in metallic PVs, the bare metallic liner of COPVs before overwrapping, and the metallic liner of new and in-service COPVs.

1.7 Due to difficulties associated with inspecting thin-walled metallic COPV liners through composite overwraps, and the availability of the NDE methods listed in Section 1.6 to inspect COPV liners before overwrapping and metal PVs, ultrasonic testing (UT) is not addressed in this standard. UT may still be performed as agreed upon between the supplier and customer. Ultrasonic requirements may utilize Practice E2375 as applicable based upon the specific liner application and metal thickness. Alternate ultrasonic inspection methods such as Lamb wave, surface wave, shear wave, reflector plate, etc. may be established and documented per agreed upon contractual requirements. The test requirements should be developed in conjunction with the specific criteria defined by engineering analysis.

1.8 In general, AE and PT are performed on the PV or the bare metallic liner of a COPV before overwrapping (in the case of COPVs, AE is done before overwrapping to minimize interference from the composite overwrap). ET, LT, and RT are performed on the PV, bare metallic liner of a COPV before overwrapping, or on the as-manufactured COPV. LP is performed on the inner and outer surfaces of the PV, or on the inner surface of the COPV liner both before and after overwrapping. Furthermore, AE and RT are well suited for evaluating the weld integrity of welded PVs and COPV liners.

1.9 Wherever possible, the NDT procedures described shall be sensitive enough to detect critical flaw sizes of the order of 1.3 mm (0.050 in.) length with a 2:1 aspect ratio.

1.10 For NDT procedures that detect discontinuities in the composite overwrap of filament-wound pressure vessels (namely, AE, ET, shearography, thermography, UT and visual examination), consult E07’s forthcoming Guide for Nondestructive Testing of Composite Overwraps in Filament-Wound Pressure Vessels Used in Aerospace Applications.

1.11 In the case of COPVs which are impact damage sensitive and require implementation of a damage control plan, emphasis is placed on NDT procedures that are sensitive to detecting damage in the metallic liner caused by impacts at energy levels which may or may not leave any visible indication on the COPV composite surface.

1.12 This guide does not specify accept/reject criteria (Section 4.10) used in procurement or used as a means for approving PVs or COPVs for service. Any acceptance criteria provided herein are given mainly for purposes of refinement and further elaboration of the procedures described in the guide. Project or original equipment manufacturer (OEM) specific accept/reject criteria shall be used when available and take precedence over any acceptance criteria contained in this document.

1.13 This standard references established ASTM Test Methods that have a foundation of experience and that yield a numerical result, and newer procedures that have yet to be validated which are better categorized as qualitative guidelines and practices. The latter are included to promote research and later elaboration in this standard as methods of the former type.

1.14 To insure proper use of the referenced standard documents, there are recognized NDT specialists that are certified according to industry and company NDT specifications. It is recommended that an NDT specialist be a part of any thin-walled metallic component design, quality assurance, in-service maintenance, or damage examination.

1.15 The values stated in metric units are to be regarded as the standard. The English units given in parentheses are provided for information only.

1.16 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use.