AS/NZS ISO 7866:2025 identically adopts ISO 7866:2012/COR 1:2014/AMD 1:2020/AMD 2:2024, which specifies minimum requirements for the material, design, construction and workmanship, manufacturing processes and tests at time of manufacture of refillable seamless aluminium alloy gas cylinders of water capacities up to and including 150 litres for compressed, liquefied and dissolved gases for worldwide use (normally up to + 65 °C).
Table of contents
Header
About this publication
Preface
Foreword
Introduction
1 Scope
2 Normative references
3 Terms and definitions
4 Symbols
5 Inspection and testing
6 Materials
6.1 General requirements
6.1.1
6.1.2
6.1.3
6.2 Thermal treatments
6.2.1 Heat-treatable alloys (see Table 1, groups 1, 3 and 4)
6.2.2 Non-heat-treatable alloys (see Table 1, group 2)
6.2.3 Control of specified heat treatment
6.3 Test requirements
6.4 Failure to meet test requirements
6.4.1
6.4.2
6.4.3
6.4.4
7 Design
7.1 General requirements
7.1.1
7.1.2
7.1.3
7.1.4
7.2 Calculation of cylindrical shell thickness
7.3 Design of ends (heads and bases)
7.3.1
7.3.2
7.3.3
7.3.4
7.4 Neck design
7.4.1
7.4.2
7.4.3
7.5 Foot rings
7.6 Neck rings
7.7 Design drawing
7.8 High-strength and/or low-elongation gas cylinder designs
8 Construction and workmanship
8.1 General
8.2 End forming
8.3 Wall thickness
8.4 Surface imperfections and defects
8.5 Neck threads
8.6 Out-of-roundness
8.7 Exposure to heat
8.8 Straightness
8.9 Mean diameter
9 Type approval procedure
9.1 General requirements
9.2 Prototype tests
9.2.1 General
9.2.2 Inspection
9.2.3 Pressure-cycling test
9.2.4 Test requirements for high-strength and/or low-elongation gas cylinder designs
9.3 Type approval certificate
10 Batch tests
10.1 General requirements
10.1.1
10.1.2
10.1.3
10.2 Tensile test
10.2.1
10.2.2
10.3 Bend test and flattening test
10.3.1 Bend test
10.3.1.1
10.3.1.2
10.3.1.3
10.3.2 Flattening test
10.3.2.1
10.3.2.2
10.3.2.3
10.4 Hydraulic burst test
10.4.1 Test installation
10.4.2 Test conditions
10.4.3 Interpretation of test
10.4.3.1
10.4.3.2
10.4.3.3
10.4.3.4
10.4.3.5
10.5 Test requirements for high-strength and/or low-elongation gas cylinder designs
11 Gas cylinder tests and examinations
11.1 General
11.2 Hydraulic test
11.2.1 Proof pressure test
11.2.2 Volumetric-expansion test
11.3 Hardness test
11.4 Leakage testing
11.5 Examination for neck folds
11.6 Marking verification
11.7 Aluminium alloy gas cylinder surface features at time of manufacture
11.7.1 Requirements
11.7.2 Imperfection considerations
12 Certification
13 Marking
Annex A
A.1 Tests for assessing susceptibility to intercrystalline corrosion
A.1.1 Principle
A.1.2 Taking specimens
A.1.3 Preparation of surface before corrosive etching
A.1.3.1 Reagents
A.1.3.1.1
A.1.3.1.2
A.1.3.1.3
A.1.3.2 Method
A.1.4 Performance of test
A.1.4.1 Corrosive solution
A.1.4.2 Preparation of the corrosive solution
A.1.4.2.1 Reagents
A.1.4.2.1.1
A.1.4.2.1.2
A.1.4.2.1.3
A.1.4.2.1.4
A.1.4.2.1.5
A.1.4.2.2 Titration of hydrogen peroxide
A.1.4.2.3 Explanation of titration
A.1.4.2.4 Preparation of the solution
A.1.4.3 Etching procedure
A.1.4.3.1
A.1.4.3.2
A.1.5 Preparation of specimens for examination
A.1.5.1 Apparatus and materials required
A.1.5.1.1
A.1.5.1.2
A.1.5.2 Method
A.1.6 Micrographic examination of specimens
A.1.7 Interpretation of micrographic examination
A.2 Test for assessing susceptibility to stress corrosion
A.2.1 Principle
A.2.2 Test specimens
A.2.3 Surface preparation before corrosion test
A.2.4 Performance of the test
A.2.4.1 Preparation of corrosive solution
A.2.4.2 Applying the stress to the rings
A.2.5 Interpretation of results
A.2.6 Possible metallographic examination
A.2.6.1
A.2.6.2
A.2.7 Test report
Annex B
B.1 Principle
B.2 General
B.3 Terms and definitions and symbols
B.4 Specimen configurations and numbers of tests
B.4.1
B.4.2
B.4.3
B.4.4
B.4.5
B.4.6
B.5 Fatigue precracking
B.6 Specimen testing procedure
B.6.1
B.6.2
B.6.3
B.6.4
B.6.5
B.6.6
B.6.7
B.6.8
B.7 Crack growth examination
B.7.1
B.7.2
B.7.3
B.7.4
B.8 Gas cylinder thickness qualification
B.9 Test report
Annex C
Annex D
Annex E
E.1 Field of application
E.2 General requirements
E.3 Leak before burst test (LBB test)
E.3.1 Flaw production procedure
E.3.2 Test procedure
E.3.2.1 General
E.3.2.2 Pressure-cycling test procedure
E.3.2.3 Constant-pressure test procedure
E.3.3 Acceptance criteria
E.3.3.1 Pressure-cycling test
E.3.3.2 Constant-pressure test
E.3.4 Parameters to be monitored
E.3.4.1 Pressure-cycling test
E.3.4.2 Constant-pressure test
E.4 Flawed gas cylinder cycle test (FCC test)
E.4.1 Flaw production procedure
E.4.2 Pressure-cycling procedure
E.4.3 Acceptance criteria
E.4.4 Parameters to be monitored
E.5 Frequency of testing
E.5.1 Prototype testing
E.5.1.1 LBB test
E.5.1.2 FCC test
E.5.2 Production testing
E.6 Specific requirements for alloys with an elongation after fracture below 12 %
