Well Omar revoked my PADI science guy certification but Im going to try this anyway.
An aluminum 80 does not hold 80 cubic feet of air (or anything for that matter), that would be enormous. What it does hold, when filled to its working pressure of 3,000 psi, is the equivalent of 80 cubic feet of air if the pressure was reduced to 14.7 psi, roughly the pressure of air at sea level not taking into account temperature and local changes in the barometric pressure.
Additionally the 80 cubic feet of an aluminum 80 is rounded up. To illustrate this check out
http://www.sportdiverhq.com/tkcht.htm. Scroll down the table to Luxfer Aluminum 77.4 which is normally referred to as an aluminum 80 yet in reality it only holds the equivalent of 77.4 cubic feet.
Lets put aside the difference between Real and Ideal gas laws, but be careful here, this is were I lost me science guy certification. For the sake of this discussion Im going to ignore the difference since its minimal; but if youre interested check out Vance Harlows Oxygen Hackers Companion which has a good description.
Using a little algebra here, if the tank holds the equivalent of 77.4 cubic feet at 14.7 psi it holds X cubic feet at the operating pressure of 3000 psi.
77.4 cf * 14.7 psi / 3000 psi = X cf = approximately 0.38 cubic feet
If you scroll down the table to Pressed Steel 100.1 and apply the same formula youll get:
100.1 cf *14.7 psi / 3500 psi = X cf = approximately 0.42 cubic feet
So comparing the two you can see that the actual volume of the tank is not much different, 0.38 versus 0.42, but since the HP100 has a higher working pressure it holds more air if both are filled to their respective working pressure.
To take it a step further; if you filled the HP100 to 3000 psi what would the volume be? Trick question, the volume would still be 0.42, but at a higher pressure. O.K. the real question; if you filled the HP100 to 3000 psi what would the volume of air be if the pressure were reduced to 14.7 psi?
0.42 cubic feet * 3000 psi / 14.7 psi = x cubic feet = approximately 85.7 cubic feet
Hope this helps,
Mike