I'd be curious to know about cylinder rupture data during hydrotest. Of course, because the cylinder is filled with a non-compressible fluid and protected in a water jacket, there's no risk of hydrotesters getting blown up, but it would be interesting to know how many cylinders, scuba and otherwise, actually rupture when subjected to test pressure.
I have seen a few. It is not common, but it happens.
When it happens it is a mess. There is a large burst disc on the side of the water jacket to relief the stored energy. The disc is about 6 inches in diameter. Even do that water is virtually non compressible all materials in the system are elastic (and there is a little bit of air in the gauge). Therefore there is some stored elastic energy.
About two years ago my LDS had a cylinder rupture (I think it was there first time) and it made a major impression on the operator. There very little danger, but it doesn't go unnoticed.
Then you have to clean up the mess because the relief is halfway down the water jacket.
I have seen both steel and aluminum cylinders that have rupture during test. I have seen more steel, but that is only because that was all we had when I ran the hydro machine (in the 70's).
Again, I have only seen a few and I don't think it is very common.
The hydro pressure is only supposed to reach the low end of the yield stress. If the cylinder ruptures at that stress level it means two things. It has lost strength and most likely it is also brittle. A ductile cylinder, the operator may notice an increase in deformation rate at the high stresses (but this may not be always obvious).
I don't know the previous history of steel cylinder that ruptured (in my old LDS). I was only present during a couple and I only remember being the operator in occasion.
I do remember that at least one of the cylinders was a converted O2 or CO2 cylinder used in for scuba (that was very common).
I remember more that once having to remove the wire wound cylinder to do hydro test. The wire windings were done for fragmentation protection on WW-II cylinders used with O2 in aircrafts during the war. The cylinders were perfectly legal to be hydro and re-certified, but the wire had to be removed. It seem like it was miles of wire wrapping those cylindes.