Minutes of Meeting

NCRB-A SC-3 # 203

Date: 23.11.2023 14:30 hours Thursday
Venue: MCD Conference Hall, INSTEF Area

No. of cases discussed: 6 (1, 2, 3, 4, 5 & 6)

SN Case # Discussions and Dispositions

1 203-1 Ref: Case # 199-4

Item: Plungers realised from Saarloha supplied material (GY XSR 2936).
Issue: Leak was observed in the housing of Ø12.7 mm NC Pyro Valve
(ID # GY-0090 / 1-1 / J11) realised from AISI 304L, Ø50 mm,
XSR 2874 supplied by Saarloha. Failure was presented in FAB-1
and the committee recommended obtaining clearance from an
appropriate forum before usage of all Saarloha supplied batches of
materials / components realised.
System: CM-CES - ASMG applications.

Discussions and observations:

a) Plungers are used in Crew Module Adaptor Retraction System (CMAS) of
CM-CES. These are used in latching the CMAS during retraction thereby
the retracted structure does not cause any damage to the CM.
b) Plungers (83 Nos., ID given in Annexure 1) were realised from
GY XSR 2936 / 18 & 20, Ø40 mm AISI 15-5 PH rods supplied by
Saarloha.
c) Designer has indicated that Plunger is not a load bearing member and is
basically used to hold the CMAS after retraction. Margin availability on the
design was indicated as 1.7.
d) Designer was asked provide revised margin considering a defect of
70 µm size which was the maximum size of inclusion observed in
XSR 2874. Designer reported that even with 1 mm defect, design margin
reduces to only 1.65. Hence, the presence of ESR inclusion (if any) will
not have any impact on the functioning of the component.
e) MMF informed that an internal rejection of ~240 mm length was there for
this batch at Saarloha during processing.
f) All the Plungers were subjected to visual inspection and no observation of
inclusions seen.
g) Plungers realised from the same batch of material GY XSR 2936 had
flown successfully in TV-D1 flight.
 SN Case # Discussions and Dispositions

Recommendations:
Plungers (83 Nos., ID given in Annexure 1) realised from GY XSR 2936 were
accepted.

2 203-2 Action Closure

Ref: Case # 192-1
Item: AA2219 T852 Forgings
GY XNF 11858 / 1 - 20 120  120  500 mm
GY XNF 11943 / 1 - 41 Ø270  100 mm

System: C25 Fluid System Elements - Gaganyaan.

Deviation: Microstructure not meeting the specification.
SC3 Action: Following subcommittee was formed to look into the deviation and
come out with a recommendation:
1) Dr. Rohit Kumar Gupta, MCTG / MME
2) Mr. Arun Dwivedi, QCM / MME.

Discussions and observations:

a) Subcommittee had a detailed review of the microstructures and presented
the observations:
1) Minor coring / segregation was seen at higher magnification in
microstructures of billets used for conversion.
2) EDS analysis on the suspected locations revealed a minor localised
segregation of V & Ti (though close to the specified limits of AA 2219
alloy). As these elements have lesser diffusivity as compared to
other elements, these tend segregate locally. No other chemical
inhomogeneity was noticed.
3) Probable root cause for the minor segregation in the forgings is
attributed to the input billet.
4) It was also informed that extensive studies including SCC evaluation
were carried out in the past on similar observations and it was
proven that no detrimental effect on account of the microstructural
features. Refer NCRB-A SC-3 Meeting # 170, Case # 170-9.
b) As no deviation in mechanical properties seen, microstructure was
accepted.

Recommendations:
Microstructure deviation in the above referred AA 2219 T852 forgings were
accepted.

NCRB-A SC-3 MoM #203 Page 2 of 8

 SN Case # Discussions and Dispositions

3 203-3 Item: AISI 17-4 PH Rods GY XSF 209 Ø230 mm

System: HS200 Separation Systems & TVP applications.
Deviation: Solution treated hardness was more.

Discussions and observations:

a) Solution treated hardness was 374 to 395 against the specification of
363 BHN maximum.
b) Rod was air cooled till 350° C and then furnace cooled till ambient
temperature to avoid cracking during transformation.
c) Response to ageing at H1025 condition demonstrated on samples from
both ends of rod.
d) Higher solution treated hardness shall not have an impact on the end use
of the rod.

Recommendations:
Solution treated hardness deviation in 17-4 PH rod, GY XSF 209, was
accepted as the response to ageing at H1025 condition was satisfactory.

4 203-4 Ref: Case # 199-4

Item: Shear Pins realised from Saarloha supplied material (XSR 2796).
Issue: Leak was observed in the housing of Ø12.7 mm NC Pyro Valve
(ID # GY-0090 / 1-1 / J11) realised from AISI 304L, Ø50 mm,
XSR 2874 supplied by Saarloha. Failure was presented in FAB-1
and the committee recommended obtaining clearance from an
appropriate forum before usage of all Saarloha supplied batches of
materials / components realised.
System: SCM.

Discussions and observations:

a) Shear Pins (64 Nos., ID Nos. as given below) for SCM were realised at
Manjira from Saarloha supplied material - 35NCD16, Ø20 mm:
XSR 2796 / 06, 08, 18, 76 & 78.

SN Description ID Qty.

1 SCM Compact PRU Shear Pin - 1 M1 50

2 SCM Apex Structure Shear Pin - 1 M2 70
3 SCM Apex Structure Shear Pin - 2 M3 180
4 SCM Apex Structure Shear Pin - 5 M4 20
b) All Shear Pins were subjected to visual inspection and no evidence of

NCRB-A SC-3 MoM #203 Page 3 of 8

 SN Case # Discussions and Dispositions

inclusions seen.
c) Committee felt that designer assessment on the margins with 70 µm
defect (assuming the presence of an ESR inclusion of the same size
observed in XSR 2874) to be obtained to take a call on disposition for
these pins.
d) XSR 2796 / 03, 11, 14, 67 & 68
It was informed Shear Pins for the first set of SCM at L&T were realised
from these rods. On account of CM damage, said Shear Bolts were
sidelined.
Balance material from the above were available in rod form and
disposition of rods was sought by the originator.

Recommendations:
a) Shear Pins Refer table in paragraph ‘a’
Designer assessment with 70 µm defect shall be obtained and presented
for the disposition of Shear Pins realised from XSR 2796 / 06, 08, 18, 76
& 78.
Action: MMF
b) XSR 2796 / 03, 11, 14, 67 & 68
The following shall be carried out and presented:
1) Macro check on both ends of all the 5 rods and
2) Visual inspection of Shear Bolts at 5X magnification.
Action: MMF

5 203-5 Item: Slotted Cheese Head Screw

GY JS - 974 / 23 M1.6  0.35  5 35,500
GY JS - 975 / 23 M1.6  0.35  6 4,850
GY JS - 965 / 23 M1.6  0.35  10 2,42,000
System: Electronic packages.
Deviation: a) Less head height and
b) Less un-grooved dimension.

Discussions and observations:

a) Details of deviations:

SN Description Unit Specification Observed

1 Standard - IS:1366 : 2002 IS:1366 : 1982

2 Head Height mm 0.96 / 1.10 0.88 / 0.93
3 Un-grooved Dimension mm > 0.4 0.39 / 0.46

NCRB-A SC-3 MoM #203 Page 4 of 8

 SN Case # Discussions and Dispositions

b) Root Cause
The root cause of these deviations was obsolete standard was followed:
IS:1366 : 1982. As per this standard the head height and un-grooved
dimension requirements were lower.
In future, the version of the current standard shall be mentioned in the
indent in addition to the condition that latest version shall be followed.
c) It is relevant to note that all the dimensions except the head height and
un-grooved dimension met the latest standard IS:1366 : 2002.
d) Un-grooved Dimension
Un-grooved dimension (w) was not reported. But this was computed from
the reported values of head height and slot depth. The range of
un-grooved dimension was 0.39 - 0.46 mm.
e) Torque Test
As lower head height and lesser un-grooved dimension might affect the
torqueing capability of fasteners, torque test was carried out on 20
additional samples from each size.
Failure torque of 0.5 was observed against specification of 0.2 Nm.
Moreover, failure was observed in the slot and not at the head of the
fasteners, indicating that these deviations did not affect the functionality.

Recommendations:
a) The following Slotted Cheese Head Screws were accepted:
GY JS - 974 / 23,
GY JS - 975 / 23 &
GY JS - 965 / 23.
b) In future, the version of the current standard shall be mentioned in the
indent in addition to the condition that latest version shall be followed.

6 203-6 Item: Ratification of LSC Minutes of Meeting

Reference: MoM #098 FTD / LSC / 098.

Discussions and observations:

Mr. Saumya Pratap Singh presented the details of LSC (Casting) Minutes of
Meeting of 098.

Recommendations:
LSC (Casting) Minutes of Meeting 098 was ratified.

NCRB-A SC-3 MoM #203 Page 5 of 8

 Prepared by

Gino Prakash Srinath J Saumya Pratap Singh

Convener, NCRB-A SC-3 Convener, NCRB-A SC-3 Convener, NCRB-A SC-3
Ferrous / Non-Ferrous alloys Fasteners / AM Products Castings / Ceramics / MPD /
SMF / Special Products

Approved by

Madhukar R Marur
Chairman, NCRB-A SC-3

Dr. / Mr. / Ms.

SN Participants SN Invitees

1 Madhukar R Marur, Chairman 1 Rajiv Panda, MMNF

2 Immanuel Inbaraj T, QDLS 2 Pabitra Mohan Nayak, MMNF
3 Rohit Kumar Gupta, MCTG 3 Karthikeyan MK, MMF
4 Shunmugavel, QCM 4 Balvinder Singh Bhatia, MMF
5 Sudarsana Rao G, MTD 5 Naresh Kumar, MMA - HWC
6 Anil Kumar V, MPA 6 Shivaram BVRN, MMA - HWC
7 Resmi SS, SED 7 Nitesh N, QCM
8 Gino Prakash, Convener 8 Arun Dwivedi, QCM
9 Srinath J, Convener 9 Gowri Shankar, QCM
10 Saumya Pratap Singh, Convener 10 Saikrupa, QC-HWC
11 Vivek, MPA
12 Vikas Kumar, FDA
13 Jagannathan K, MDAD
14 Gantawar S Jitendra, MDAD
15 Md Perwaiz Alam, SSMD

NCRB-A SC-3 MoM #203 Page 6 of 8

 Annexure 1

Identification details of Plungers realised from GY XSR 2936 / 18 & 20 and

subjected to visual inspection

SN Component ID SN Component ID

1 GY - 2123 / 18 / CA 09 28 GY - 2123 / 18 / CA 67
2 GY - 2123 / 18 / CA 10 29 GY - 2123 / 18 / CA 68
3 GY - 2123 / 18 / CA 17
4 GY - 2123 / 18 / CA 19 30 GY - TRP - 4304
5 GY - 2123 / 18 / CA 22 31 GY - TRP - 4305
6 GY - 2123 / 18 / CA 23 32 GY - TRP - 4306
7 GY - 2123 / 18 / CA 26 33 GY - TRP - 4307
8 GY - 2123 / 18 / CA 28 34 GY - TRP - 4308
9 GY - 2123 / 18 / CA 31 35 GY - TRP - 4309
10 GY - 2123 / 18 / CA 36 36 GY - TRP - 4310
37 GY - TRP - 4311
11 GY - 2123 / 18 / CA 37 38 GY - TRP - 4312
12 GY - 2123 / 18 / CA 40 39 GY - TRP - 4313
13 GY - 2123 / 18 / CA 41 40 GY - TRP - 4314
14 GY - 2123 / 18 / CA 42
15 GY - 2123 / 18 / CA 45 41 GY - TRP - 4315
16 GY - 2123 / 18 / CA 46 42 GY - TRP - 4316
17 GY - 2123 / 18 / CA 49 43 GY - TRP - 4317
18 GY - 2123 / 18 / CA 52 44 GY - TRP - 4318
19 GY - 2123 / 18 / CA 53 45 GY - TRP - 4319
20 GY - 2123 / 18 / CA 54 46 GY - TRP - 4320
47 GY - TRP - 4321
21 GY - 2123 / 18 / CA 55 48 GY - TRP - 4322
22 GY - 2123 / 18 / CA 57 49 GY - TRP - 4323
23 GY - 2123 / 18 / CA 59 50 GY - TRP - 4324
24 GY - 2123 / 18 / CA 60
25 GY - 2123 / 18 / CA 62 51 GY - TRP - 4325
26 GY - 2123 / 18 / CA 65 52 GY - TRP - 4326
27 GY - 2123 / 18 / CA 66 53 GY - TRP - 4327

NCRB-A SC-3 MoM #203 Page 7 of 8

 SN Component ID SN Component ID

54 GY - TRP - 4328 81 GY - TRP - 4355

55 GY - TRP - 4329 82 GY - TRP - 4356
56 GY - TRP - 4330 83 GY - TRP - 4357
57 GY - TRP - 4331
58 GY - TRP - 4332
59 GY - TRQ - 4333 1
60 GY - TRP - 4334

61 GY - TRP - 4335
62 GY - TRP - 4336
63 GY - TRP - 4337
64 GY - TRP - 4338
65 GY - TRP - 4339
66 GY - TRP - 4340
67 GY - TRP - 4341
68 GY - TRP - 4342
69 GY - TRP - 4343
70 GY - TRP - 4344

71 GY - TRP - 4345
72 GY - TRP - 4346
73 GY - TRP - 4347
74 GY - TRP - 4348
75 GY - TRP - 4349
76 GY - TRP - 4350
77 GY - TRP - 4351
78 GY - TRP - 4352
79 GY - TRP - 4353
80 GY - TRP - 4354

1
GY - TRQ - 4333 is marked on the
component. However, the identification in the
dimensional report is GY - TRP - 4333.

NCRB-A SC-3 MoM #203 Page 8 of 8