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Transition joints are crucial in engineering, connecting dissimilar materials for structural integrity in applications like aerospace and marine engineering. Specifically, in the ISRO's C25 cryogenic stage for the Gaganyaan mission, bimetallic transition joints, comprising ICSS-1218–321 and Ti5Al2.5Sn-ELI, play a pivotal role. They facilitate the connection of gas bottles containing cold GHe to plumb lines submerged in an LH2 tank at 20 K. To address the challenges posed by joining of dissimilar materials, the selected material combination incorporates pure aluminum AA1050 as a compatible interlayer. Additionally, in overcoming the difficulties associated with conventional fusion welding, a solid-state joining process, specifically friction welding, is employed to realize these bimetallic joints. Considering the critical service conditions of the Gaganyaan mission and the metallurgical complexities inherent in achieving a transition joint configuration, this study offers a comprehensive overview into the process optimization of the weld joint, metallurgical characterization of the interface, and qualification/acceptance tests conducted on the friction-welded ICSS-1218–321 + AA1050 + Ti5Al2.5Sn-ELI bimetallic transition joints, intended for use in cryogenic gas bottles for human-rated applications.

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Development and Qualification of Friction Welded Bi-Metallic Transition Joints of ICSS-1218–321 and Ti5Al2.5Sn (ELI) for C25 Stage for Gaganyaan Application

  • 会议论文

  • 发表日期：

    2026年

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  • Sandipan Das,
  • J. Cyriac,
  • S. V. S. Narayana Murty,
  • M. Arumugam

摘要

Transition joints are crucial in engineering, connecting dissimilar materials for structural integrity in applications like aerospace and marine engineering. Specifically, in the ISRO's C25 cryogenic stage for the Gaganyaan mission, bimetallic transition joints, comprising ICSS-1218–321 and Ti5Al2.5Sn-ELI, play a pivotal role. They facilitate the connection of gas bottles containing cold GHe to plumb lines submerged in an LH2 tank at 20 K. To address the challenges posed by joining of dissimilar materials, the selected material combination incorporates pure aluminum AA1050 as a compatible interlayer. Additionally, in overcoming the difficulties associated with conventional fusion welding, a solid-state joining process, specifically friction welding, is employed to realize these bimetallic joints. Considering the critical service conditions of the Gaganyaan mission and the metallurgical complexities inherent in achieving a transition joint configuration, this study offers a comprehensive overview into the process optimization of the weld joint, metallurgical characterization of the interface, and qualification/acceptance tests conducted on the friction-welded ICSS-1218–321 + AA1050 + Ti5Al2.5Sn-ELI bimetallic transition joints, intended for use in cryogenic gas bottles for human-rated applications.