FD
Welcome to ScubaBoard.
As you mentioned, it is important how we post information, but IMHO, it is even more important that we don't spread wrong information.
Your statements on your last post about metal fatigue are incorrect. The number of pressure cycles a tank receive even if they are filled daily are very small and the design stress level (if they are not overfilled) is low enough that a cylinder will endure many... many decades. This is not just theoretical these are also facts based on observations of cylinders that are many decades old.
The stress cycles are also none reversing (the stress is only positive) so the fatigue life is much higher than in reversing loads.
You ought to read Pete Johnson (Gilldiver) post number 24 on the thread below:
http://www.scubaboard.com/forums/tanks-valves-bands/277122-life-aluminum-age-cycles-based.html
What kills most tanks is corrosion, not pressure cycles. Heat, as in a fire, will also destroy the heat treatment of most cylinder alloys. This is the case for aluminum or steel, but aluminum is affected by much lower temperatures.
The reason hydro test are performed is because it is an easy inexpensive way of doing non-destructive testing that indirectly checks material condition and material stress (as a function of deformation/ strain). Since corrosion (a.k.a. rust in the case of steel) is the major destructive cause of steel cylinders, visual inspections can be in many ways more important than hydro tests.
BTW, since we are posting credentials:
I stated working in a dive shop almost 40 years ago. I did regulator repairs, tank inspections, and hydro tests shortly after I started at that shop. Since then I have helped on many other shops, most recently only as a technical consultant.
I have over 30 years of engineering experience with a couple of engineering degrees, one in mechanical engineering. In part of my career, I have design many pressure vessels including ASME code pressure cylinders.
Only recently I took some of PSI/PCI tank inspection certification courses (as I mentioned I have been doing VIP for almost 40 years), in exchange for some engineering consulting I have done for PSI.
If you read through my post, I hope you can notice that I always try to make it clear when I am posting my opinion versus a fact. If I am posting a fact (unless I make a mistake, which I have done and I am sure to do again) it means that I can back it up with printed information or my own calculations. In some of my posts I try to include references when it is convenient.