Pressure Vessel and COPV Testing

Element helps you qualify COPVs and pressure vessels for demanding operational environments. From burst and proof testing to fatigue and cyclic pressure evaluation, Element delivers integrated testing solutions that reduce risk, support certification, and validate performance for aerospace, defense, and energy applications.

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What is Pressure Vessel and COPV Testing at Element?

Pressure vessel and composite overwrapped pressure vessel (COPV) testing evaluates the structural integrity, durability, and safety of pressurized systems operating in demanding environments. These systems are commonly used in aerospace, defense, and energy applications. At Element, pressure vessel and COPV testing combines pressure, mechanical, and environmental testing capabilities to support development, qualification, certification, and failure analysis programs.

What Can Element Offer You For Pressure Vessel and COPV Testing?

Element testing specialist standing among environmental test chambers in product testing lab

Key tests offered

Element performs hydrostatic and pneumatic pressure testing, burst and proof pressure testing, fatigue and cyclic pressure testing, leak testing, and structural integrity evaluations. These comprehensive tests validate vessel performance under operational and extreme conditions, supporting development and qualification programs for aerospace, defense, and energy applications.

Burst testing
Proof pressure testing
Cyclic fatigue testing
Leak testing
Pressure decay testing
Stress rupture evaluation

Components and materials we test

Element tests composite overwrapped pressure vessels (COPVs), metallic pressure vessels, fuel and propellant tanks, accumulators, and pressurized assemblies used in aerospace, defense, and energy applications. Materials tested include carbon fiber composites, aluminum, titanium, polymers, and high-strength alloys designed for high-pressure environments.

Methods and solutions offered

Element supports full lifecycle qualification programs from R&D through certification and failure analysis. Testing programs simulate operational conditions through pressure, fatigue, thermal, and mechanical loading scenarios to validate long-term durability and structural performance.

Cutting-edge equipment we use

Element utilizes high-pressure test systems, large-scale test rigs, and environmental chambers capable of evaluating pressurized systems under operational and extreme loading conditions.

Standards we test to and Components we test

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Aerospace & Space Standards

ANSI/AIAA S-081B-2018 – Space Systems: Composite Overwrapped Pressure Vessels
ANSI/AIAA S-080A-2018 – Space Systems: Metallic Pressure Vessels
ISO 14623 – Space Systems: Pressure Vessels and Pressurized Structures
NASA-STD-6016 – Standard Materials and Processes Requirements for Spacecraft
MIL-STD-810 – Environmental Engineering Considerations

Pressure Vessel Standards

ASME Boiler & Pressure Vessel Code (BPVC)
ISO 11119 – Gas Cylinders: Composite Cylinders
DOT / CFR Title 49
API 510 – Pressure Vessel Inspection Code

ASTM Standards

ASTM D1599
ASTM D2992

Your Challenges, Our Solutions

Prevent catastrophic failure

Element validates vessels through burst, fatigue, and structural integrity testing to help identify weaknesses early and ensure safe performance under demanding pressure conditions.

Meet strict requirements

Element supports aerospace, defense, and energy qualification programs with testing aligned to industry standards and customer-specific requirements.

Validate long-term durability

Element evaluates pressure vessels under cyclic pressure, fatigue, thermal, and mechanical loading conditions to assess long-term structural reliability.

Reduce testing delays

Element’s integrated testing capabilities reduce reliance on multiple vendors, helping streamline qualification programs and accelerate time to market.

Why Choose Element

Aerospace-focused expertise

Supporting critical aerospace and defense qualification programs

Integrated testing solutions

Pressure, materials, and environmental testing from one provider

Global testing network

Consistent support across key aerospace and energy regions

Trusted risk reduction

Helping validate safety and long-term vessel performance

Frequently asked questions

When should a pressure vessel undergo qualification testing?

Pressure vessel qualification testing should be conducted during product development, prior to certification, after significant design changes, or when required by customer, industry, or regulatory standards. Qualification testing helps demonstrate that the vessel can safely perform under expected operating conditions.

What is the difference between proof testing and burst testing?

Proof testing verifies that a pressure vessel can safely withstand a specified pressure without permanent deformation or failure. Burst testing increases pressure until the vessel fails, providing data on ultimate strength and safety margins.

Why are COPVs used instead of traditional metallic pressure vessels?

COPVs offer a high strength-to-weight ratio, making them ideal for applications where weight reduction is critical, such as aerospace, defense, and space systems. Their lightweight construction can improve efficiency while maintaining pressure containment performance.

What factors can affect the lifespan of a pressure vessel?

Pressure cycling, operating pressure, temperature exposure, material properties, manufacturing quality, and environmental conditions can all influence pressure vessel longevity. Testing helps identify potential failure mechanisms before they impact performance.

Can pressure vessel testing be customized to unique operating requirements?

Yes. Testing programs can be tailored to simulate customer-specific operating environments, loading conditions, pressure cycles, and performance requirements to generate meaningful qualification data.

What information is needed before starting a pressure vessel test program?

Typical requirements include engineering drawings, material specifications, operating pressure ranges, design requirements, applicable standards, and intended service conditions. This information helps develop an appropriate test plan.

How does pressure vessel testing support risk reduction?

Testing identifies design weaknesses, manufacturing defects, and potential failure modes before a product enters service. Early identification of issues can reduce costly redesigns, delays, and field failures.

What industries commonly require COPV testing?

COPV testing is commonly used in aerospace, space exploration, defense, energy, and advanced transportation applications where lightweight, high-pressure storage systems are required.