A pressure vessel, which was designed and tested under laboratory conditions for tens of thousands of cycles, failed in service after only a few cycles. Thousands of oscillatory pressure reversals were measured at each loading. However, the predominance of the stress amplitudes were well below the critical threshold values necessary to initiate fatigue cracking. Analysis demonstrated that the disparity between lab cycling and field loading conditions could not be explained simply by mechanical loading alone. Further investigation into the problem revealed that an extremely aggressive environment, the by-products of the internal combustion from within the pressure vessel, along with high temperatures, pressures, and other sources of high tensile loading all contributed to the short fatigue life of the vessel.
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