Pressure vessel autofrettage system

for high-pressure applications

Product Overview
Autofrettage Machines by Poppe + Potthoff Maschinenbau are designed to improve the fatigue strength and service life of high-pressure components such as common rails, pump heads, diesel injection lines, tubes, pipes, and other pressure vessels. These machines are capable of generating and controlling autofrettage pressures up to 16,000 bar, ensuring exact reproducibility and compliance with international standards. The autofrettage process involves pressurizing a component’s inner wall beyond its elastic limit, creating a permanent compressive stress layer after pressure release, which prevents crack initiation and delays fatigue failure. This allows for reduced wall thickness without compromising strength, safety, or service life.

Applications of the Autofrettage Process

• Common rail systems and fuel injection lines
• High-pressure connectors, cross fittings, and pump heads
• Hydraulic pump housings, liners, and jackets
• High-pressure nozzles and other pressure vessels
• Defense applications such as gun barrels and cannon tubes
• COPV Tanks (with water) up to 1050 bar

Autofrettage Machine Types and Features

• Multipurpose Autofrettage Machine: Ideal for research, development, and small series production. Suitable for pipes, lines, valves, rails, pump heads, sensors, and other pressure vessels. Features variable geometry handling, programmable parameters, and a hydraulically-driven pressure intensifier.
• Serial Production Autofrettage: Equipped with a hydraulic pressure intensifier, automatic tensioning, and safety features. Suitable for injector nozzles, injection lines, pump heads, and supports various automation levels.
• Injection Line Autofrettage: Designed for high-pressure diesel injection lines, supports up to 10 lines at once, programmable pressure, and real-time monitoring.
• Extendable Autofrettage: Independent unit for diesel injection lines up to 8,000 bar, upgradeable to 10,000 or 12,000 bar, and expandable to multi-chamber systems (up to 6 chambers).
• R&D Autofrettage Machine: Flexible for prototypes and development, freely programmable pressure, ergonomic control panel, and supports conversion for different component types.
• Autofrettage COPV: Designed for composite overwrapped pressure vessels (COPVs) using water as the test medium, up to 1050 bar, with automated pre-filling, pressure hold, and full data capture.

Performance Data (by machine type)

• Multipurpose Autofrettage: Pressure up to 16,000 bar, changeable devices for round/cubic geometries, programmable pressure increase, electronic data acquisition.
• Serial Production: Pressure up to 12,000 bar, high component variability, automatic tensioning (200–1,300 mm), various automation levels.
• Injection Line: Up to 9,000 bar (upgradeable to 12,000 bar), supports up to 5 injection line types, 10-position station, custom fixture design.
• Extendable: 8,000/10,000/12,000 bar, 1–6 chambers, manual placement, automatic clamping/venting, complete documentation.
• R&D: 16,000 bar, flexible mounting, ideal for prototypes and R&D.
• COPV: Water as medium, up to 1050 bar, configurable dimensions, automated pre-filling, stable pressure hold, rigid safety chamber, Siemens PLC with HMI, remote support.

Industries Served

• Automotive
• Aerospace
• Home Appliances
• Medical Technology
• Shipbuilding
• Oil & Gas

Caractéristiques / Spécifications techniques

• Maximum autofrettage pressure: up to 16,000 bar (machine dependent)
• Pressure medium: Water (for COPV), hydraulic oil (for intensifiers)
• Component compatibility: Common rails, injection lines, pump heads, COPVs, gun barrels, pressure vessels, etc.
• Automation: Manual to fully automated, programmable parameters, remote support
• Fixture design: Customizable for various geometries and sizes
• Data acquisition: Electronic, with full traceability (pressure curve, hold time, expansion volume, temperature, etc.)
• Safety: Rigid steel chambers, automatic doors, safety windows, compliance with safety directives
• Upgradeability: Multi-chamber options, pressure upgrades, modular design