Low‐thickness/diameter cylindrical storage pressure vessels with composite overwrapping fail at diverse internal and external pressure circumstances, causing several faults that must be included and minimized to retain effectiveness and working capability. The bursting effect is caused by hoop (internal) stresses and can be reduced by composite lamination alignment and internal pressure resistance. Pressure vessel bursting faults vary with internal tensions and can induce fiber reinforced polymer fracture and composite cylinder failure under many failure criteria. Micro‐mechanical nondestructive testing uses independent failure criteria associated to modes like Tsai‐Wu, Tsai‐Hill, Azzi‐Tsai, Hoffman, and Chamis. Micro‐cracking of composite layers generates delamination in composite pressure vessels, causing porosity. Pressure vessel micro‐cracking was assessed using classical laminate theory. Composite material strain‐rate failures in mobile applications like hydrogen storage cars with composite pressure vessels are examined due to their widespread use. Finally, Polar, Helical, and Hoop winding sequences are consistently focused to optimize the design and analyze the parameters for the overall impact of different failure aspects as bursting behavior in cylindrical composite pressure vessels. Type‐IV composite pressure vessels have the best results due to their lightest weight but complexity of winding over the polar head geodesic and non‐geodesic curvatures overwrapped carbon include all these internal composite and liner geometry faults and optimize them to reduce failure issues to fix composite overwrapped pressure vessels (COPV's) design. Liner‐less composite pressure vessels (Type‐V) need more design and production study for high‐pressure and temperature applications.Highlights
Failure deals with the internal and external pressures exerted on composite pressure vessels.
Failures like bursting of the pressure vessel, due to like micro‐cracking, delamination's and strain‐rate failures of composites.
Failures detection through NDT inspection for polymer composite materials for composite pressure vessels.
(COPV) perfect lamina sequence, liner materials and fiber winding angles must be considered for designing state of the art liner‐less Type‐V pressure vessels.
Independent Failure criteria like (Tsai‐Wu & Hashin).
