John,
Nice piece of engineering/fabrication! I'm impressed. We used to make chemical (lighter fluid) cannons from steel soda pop cans (about 6 cans, taped end to end). A slightly used tennis ball was just about the perfect fit (and not too deadly -- though you still wouldn't want to be on the receiving end). Oranges work, too.
Lighter fluid (just a couple of drops) was squirted into the back of the cannon through a small hole. Spin the cylinder to spread the fluid, allow to vaporize. Grasp the cannon firmly with both hands, tucking it under one arm. Someone else applies a match to fuel port. I leave the rest to your imagination. (PS Steel shrapnel is easily detectable with X-rays. Fortunately we avoided need for such.)
I must confess, we didn't do a rigorous analysis of the design, since we were lacking information on loads resulting from a chemical explosion. We just started with very small amounts of "propellant" and derived the optimal amount empirically. (Being considerably older now, and perhaps slightly(?) wiser, I cannot recommend this approach to the public at large.)
Your point about the dangers of compressed gases is spot on. I recommend you calculate hoop stresses of all components. Also calculate longitudinal/tension loads for end cap and joint failures. A factor of safety of 4.0 is a minimum for pressure vessels. A factor of safety of 10.0 is used on items involved in human safety. Securing your cannon prior to pressurizing/firing might also be a good idea (perhaps by laying a sand bag on it). Just some thoughts from a fellow enthusiast...
The engineering physics sounds rather useful. Could you please design a good fusion reactor.
The world is in bad need of one. (They're hoping the one being built in southern France will get them above the break even point.) It will be a pleasant change when we can leave hydrocarbon fuels behind -- and also not have to worry about nuclear waste that lasts for tens of thousands of years.
Enjoy your summer!
Bill