Life Prediction Methods for Composite Over-wrapped Pressure Vessels (MSC P1T39-316)

The Army and other Department of Defense (DoD) agencies make extensive use of composite over-wrapped pressure vessels (COPV); applications include missile sensor cooling containers to gas storage for life-support systems. The program outlined by MaterialsSciences Corporation (MSC) focuses on conducting tests and analyses required to enable the reliable design of future COPV for a safe service life in excess of 30 years. The Phase II program will include development and demonstration of test protocols forcharacterizing the stress-rupture behavior of composite strands and laminated architectures, demonstration of analysis procedures for relating the statistical variability of unidirectional composite strand failure data to the composite laminate level andultimately the COPV level. The lifetime certification methodology to be produced by this research, and lead-the-fleet testing needed to continuously update life extension recommendations, will be demonstrated on a COPV design to be manufactured by LincolnComposites.A recent study has concluded that if the service life of these pressure vessels can be extended to as much as 30 more years, the DoD could realize an acquisitions cost savings exceeding $500M. The research proposed by MSC is expected to yieldthe statistically based test and analysis protocol necessary to design COPV for extended service lifetimes. Once derived and validated, the lifetime certification methodology will be presented to government regulatory agencies such as the NationalInstitute of Standards and Testing and the Compressed Gas Association for approval. Hence, the research program outlined in this proposal has the potential to impact virtually every COPV in the commercial market.