Interlayer Temperature Measurement Using Infrared Thermometers and Thermal Imaging Systems

1. Definition and Fundamental Principles

Interlayer temperature measurement in bimetallic cladding and weld overlay manufacturing refers to the non-contact monitoring and control of substrate and deposited layer temperatures during multi-pass welding, bonding, and post-bonding heat treatment operations. The technology employs infrared thermometers (single-point infrared guns) and thermal imaging cameras (infrared thermal imagers) to capture surface temperature distributions in real time, enabling operators to maintain interlayer temperatures within specified limits defined by welding procedure specifications (WPS) and applicable material standards.

The physical basis of infrared temperature measurement is the Stefan-Boltzmann radiation law, which states that all objects above absolute zero emit electromagnetic radiation whose intensity and spectral distribution are functions of surface temperature. Infrared thermometers measure the radiation energy in a specific wavelength band (typically 2–14 μm) from a single spot and convert it to a temperature reading. Thermal imagers extend this principle across a two-dimensional field of view, producing a spatial temperature map of the workpiece surface at a given instant. The accuracy of both devices depends critically on the emissivity of the target surface, which must be calibrated to match the actual material condition.

In the context of cladding technology, interlayer temperature is the temperature of the previously deposited layer (or base metal) at the time the next welding pass or processing step is applied. Controlling this parameter is essential to prevent excessive grain growth, avoid re-heat cracking, prevent dilution anomalies, and ensure metallurgical compatibility between layers.

2. Category and Business Positioning

This capability falls under the major category of Process Temperature Control and Cooling (过程温控与降温) and is classified under the technical direction of Interlayer Temperature Measurement (层温测量). Within the company's process control architecture, it occupies a critical position at the intersection of real-time monitoring, automated process control, and quality assurance.

The business positioning of this technology is threefold:

As noted in the capability entry, this technology is linked to entry number 324 (与324联动), indicating an integrated system architecture where temperature measurement data feeds directly into automated welding control, alarm systems, or process logging platforms.

3. Technical Purpose and Value

3.1 Primary Technical Purpose: Full-Field Non-Contact Monitoring

The stated technical purpose of this capability is full-field non-contact measurement (全场非接触). This distinguishes the approach from conventional point-contact thermocouple methods and provides several decisive advantages:

3.2 Value Chain Impact

The value delivered by this technology extends across the entire project lifecycle:

4. Key Process and Implementation Points

4.1 Single-Point Infrared Thermometer (Infrared Gun) Deployment

The single-point infrared gun is used for rapid spot-checking of interlayer temperatures at specific locations along the weld seam. The operator scans designated measurement points after each pass, recording the temperature before proceeding to the next pass. This method is appropriate for:

Key implementation parameters for single-point infrared thermometers include:

ParameterTypical SpecificationNotes
Wavelength Band8–14 μm (atmospheric window)Less susceptible to atmospheric absorption; suitable for most metal surfaces
Temperature Range−20 °C to 1,500 °C (or higher for high-temp models)Must cover base metal preheat through weld pool temperatures
Accuracy±1 °C or ±1% of readingHigher accuracy models preferred for tight interlayer limits
Spot Size / Distance Ratio (D:S)10:1 to 50:1Higher ratio enables measurement from greater standoff distance
Emissivity Setting0.75–0.95 (adjustable)Critical calibration parameter; see Section 6 for risk discussion
Response Time<1 secondEnsures captured temperature reflects current surface condition
Data LoggingInternal memory with USB/Bluetooth exportSupports traceability and digital quality records

4.2 Thermal Imager Full-Field Monitoring and Welder Interlock

The thermal imager provides continuous, full-field temperature mapping of the workpiece surface during welding operations. Its integration with the welding power source creates a closed-loop control system where:

  1. The thermal imager continuously captures the temperature distribution across the weld zone and surrounding base metal.
  2. The imaging system processes the thermal data in real time to identify maximum temperatures, average interlayer temperatures, and spatial thermal gradients.
  3. When the measured temperature exceeds the threshold defined in the WPS, the system triggers an automated alarm and may halt the welding process or activate cooling systems.
  4. Temperature data is logged with timestamps and spatial coordinates for post-process analysis and quality documentation.

Key implementation parameters for thermal imaging systems include:

ParameterTypical SpecificationNotes
Detector TypeMicrobolometer (uncooled) or InSb/HgCdTe (cooled)Uncooled for general monitoring; cooled for high-temperature welding
Thermal Resolution≤25 mK (cooled) / ≤50 mK (uncooled)Higher resolution detects subtle thermal gradients
Frame Rate≥9 Hz (typically 30 Hz or higher)Higher frame rate captures rapid thermal transients
Spatial Resolution640×480 or higherDetermines minimum detectable hot/cold spot size
Temperature Range−20 °C to 1,200 °C (multi-range)Must accommodate preheat through post-weld cooling
Emissivity CalibrationAdjustable 0.10–1.00 with material presetsMust be set for actual surface condition (bare metal, oxide, coating)
Integration InterfaceRS-232 / Ethernet / OPC / APIEnables connection to welding controller and data acquisition system
Alarm ThresholdProgrammable per WPSConfigurable upper and lower limits with configurable response actions

4.3 Emissivity Calibration — The Critical Accuracy Factor

The capability entry specifically warns about emissivity setting error (注意发射率设定误差). This is the single most common source of measurement inaccuracy in infrared temperature measurement of metal surfaces. The emissivity of a material surface determines the fraction of thermal radiation emitted relative to a perfect blackbody at the same temperature. For metals, emissivity varies significantly with:

Best practices for emissivity management include:

  1. Applying a high-emissivity target (e.g., black paint, kapton tape, or graphite paint) at designated measurement points before welding begins.
  2. Using a calibrated reference target of known temperature (e.g., a heated block with known emissivity) for in-situ verification during the welding process.
  3. Documenting the emissivity setting used for each measurement in the quality record.
  4. Periodically verifying the infrared instrument against a reference thermometer (e.g., a calibrated pyrometer or thermocouple) at known temperatures.

4.4 System Integration with Welding Control (Linkage with Entry 324)

The reference to linkage with entry 324 indicates that the temperature measurement system is not a standalone monitoring tool but is integrated into the broader automated process control architecture. The integration typically involves:

5. Applicable Standards and Acceptance Criteria

5.1 Welding Procedure Standards

5.2 Material-Specific Temperature Requirements

5.3 Inspection and Documentation Standards

5.4 Acceptance Criteria for Temperature Monitoring

Acceptance ParameterTypical CriterionVerification Method
Interlayer temperature complianceWithin ±10 °C of WPS-specified limitInfrared measurement at designated points; thermal imager full-field scan
Preheat temperatureWithin ±15 °C of specified preheat valueInfrared gun spot check at multiple locations; thermal imager uniformity check
Maximum surface temperatureNot exceeding material-specific maximum (e.g., 250 °C for 304L)Thermal imager continuous monitoring with automated alarm
Cooling rateWithin specified range (e.g., 10–50 °C/min for certain overlay grades)Thermal imager time-series analysis
Instrument calibration validityCalibration certificate current; traceable to national standardCalibration records; in-situ verification against reference thermometer

6. Common Risks and Controls

6.1 Emissivity Error

Risk: Incorrect emissivity setting leads to systematic temperature measurement error. For example, measuring bare polished stainless steel with an emissivity setting of 0.95 (appropriate for oxidized surfaces) will overestimate the actual temperature by 50–100 °C, potentially leading to unnecessary process delays or, conversely, missed exceedances if the setting is too low.

Controls:

6.2 Atmospheric Interference

Risk: Water vapor, CO₂, and particulate matter in the atmosphere absorb and scatter infrared radiation, attenuating the signal reaching the detector. This is particularly problematic in environments with high humidity, smoke from welding processes, or particulate-laden air.

Controls:

6.3 Reflected Radiation Interference

Risk: Bright surfaces (especially polished metals) reflect infrared radiation from surrounding heat sources (welding arcs, furnaces, hot surfaces), causing the instrument to read a temperature that is higher than the actual surface temperature. This is a well-known problem when measuring low-emissivity metal surfaces.

Controls:

6.4 Instrument Drift and Degradation

Risk: Infrared detectors degrade over time due to thermal cycling, exposure to high temperatures, and mechanical shock. This leads to measurement drift that may not be detected without regular calibration.

Controls:

6.5 Data Integrity and Traceability

Risk: Incomplete or unverifiable temperature records may not satisfy customer or regulatory requirements for process documentation.

Controls:

7. Application Scenarios Across the Three Technology Routes

7.1 TIG/MIG Weld Overlay Applications

In TIG (Gas Tungsten Arc) and MIG (Gas Metal Arc) weld overlay processes, interlayer temperature control is a critical process parameter that directly affects the metallurgical quality of the overlay.

Typical application scenarios:

Specific benefits in TIG/MIG overlay:

7.2 Hydraulic Explosive Bonding Applications

In hydraulic explosive bonding (also known as hydraulic explosion bonding or hydraulic shock bonding), the interlayer temperature measurement technology is applied primarily during the pre-treatment and post-treatment phases of the bonding process.

Typical application scenarios:

Specific benefits in hydraulic explosive bonding:

7.3 Explosion Welding Applications

In explosion welding, the interlayer temperature measurement technology plays a role in both the preparation phase and the post-welding quality assurance phase.

Typical application scenarios:

Specific benefits in explosion welding:

8. Contribution to Qualification Building, Product Delivery, and Customer Value

8.1 Qualification Building

Interlayer temperature measurement using infrared thermometers and thermal imagers directly supports the qualification of welding procedures and bonding processes under applicable standards:

8.2 Product Delivery

The technology contributes to product delivery in several ways:

  • Reduced rework and scrap: By preventing interlayer temperature exceedances, the technology reduces the incidence of weld defects that require rework or result in scrap. This directly improves first-pass yield and reduces production cycle times.
  • Accelerated production: Full-field monitoring eliminates the need for multiple manual thermocouple measurements, reducing the time spent on temperature verification and allowing faster progression through multi-pass welding sequences.
  • Enhanced process consistency: Automated temperature monitoring and interlock systems ensure that every production run is performed under consistent thermal conditions, reducing variability in product quality.
  • Improved traceability: Digital temperature records linked to each work order, weld map, and operator provide complete traceability from raw material to finished product, supporting customer audits and regulatory inspections.

8.3 Customer Value

The customer value delivered by this technology is substantial and multifaceted:

  • Assurance of metallurgical integrity: Customers receive products with verified interlayer temperature control, providing confidence that the cladding interface has been produced under optimal thermal conditions.
  • Extended service life: Proper interlayer temperature control prevents microstructural degradation, cracking, and corrosion susceptibility, resulting in products with longer service lives and lower lifecycle costs.
  • Reduced inspection burden: Comprehensive temperature documentation reduces the need for extensive post-weld NDT, as the process control data provides confidence in weld quality. This can translate to reduced inspection costs and faster delivery.
  • Competitive differentiation: Customers in demanding industries (oil and gas, chemical processing, nuclear power) value suppliers who can demonstrate advanced process control capabilities. The use of infrared temperature monitoring systems positions the company as a technically sophisticated and quality-focused supplier.
  • Data-driven engineering support: Accumulated temperature data from production runs can be shared with customers to support their own engineering analyses, fitness-for-service evaluations, and process optimization efforts.

9. Implementation Recommendations

9.1 Instrument Selection

  • Select infrared thermometers with a temperature range that covers the full process window (from ambient to the maximum expected surface temperature, typically up to 800 °C for welding applications).
  • Choose thermal imagers with sufficient spatial resolution (≥640×480) and thermal sensitivity (≤50 mK) to detect meaningful temperature gradients across the workpiece surface.
  • Ensure instruments have programmable alarm thresholds and data logging capabilities to support automated process control and quality documentation.
  • Verify that instruments have appropriate environmental ratings (IP65 or higher) for use in manufacturing environments with dust, moisture, and fumes.

9.2 Calibration and Maintenance

  • Establish a calibration program with intervals based on instrument usage frequency and criticality of the application (typically 6 months for high-criticality applications, 12 months for general monitoring).
  • Maintain calibration records traceable to national standards (e.g., NIST-traceable in the United States, or equivalent national metrology institute standards).
  • Implement a pre-use verification procedure that includes a check against a reference thermometer at a known temperature.
  • Store instruments in protective cases when not in use and avoid exposure to extreme temperatures or mechanical shock.

9.3 Operator Training

  • Train operators on the principles of infrared temperature measurement, including the effects of emissivity, atmospheric conditions, and reflected radiation.
  • Conduct hands-on training on instrument operation, including emissivity setting, measurement technique, and data logging.
  • Implement a qualification program that certifies operators to perform interlayer temperature measurements independently.
  • Include infrared temperature measurement in the company's WPS qualification training curriculum.

9.4 System Integration

  • Integrate the thermal imager with the welding power source controller to enable automated interlayer temperature gating and alarm functions.
  • Connect the data acquisition system to the company's QMS for automated generation of temperature records and quality documentation.
  • Implement a data retention policy that ensures temperature records are stored for the required period (typically the life of the product plus a minimum of 5–10 years, depending on industry requirements).
  • Establish interfaces with the company's NDT systems to correlate temperature data with inspection results for comprehensive quality assurance.

10. Conclusion

Interlayer temperature measurement using infrared thermometers and thermal imaging systems is a foundational capability in modern bimetallic cladding and weld overlay manufacturing. It bridges the gap between process design and process execution, ensuring that the thermal conditions specified in welding procedure specifications are maintained throughout production. The combination of single-point infrared guns for rapid spot-checking and thermal imagers for full-field monitoring provides a comprehensive temperature measurement capability that supports process control, quality assurance, and regulatory compliance across all three of the company's technology routes: TIG/MIG weld overlay, hydraulic explosive bonding, and explosion welding.

The critical importance of emissivity calibration cannot be overstated. Proper management of this parameter is essential to achieving measurement accuracy that supports confident process control decisions. Organizations that invest in rigorous emissivity management, regular calibration, and operator training will realize the full value of infrared temperature measurement technology in their cladding operations.

As the industry moves toward greater automation and digitalization, the integration of infrared temperature measurement systems with welding controllers, data acquisition platforms, and quality management systems will become increasingly important. The company's capability in this area, particularly the linkage with automated welding control systems, positions it to deliver products with superior process control, enhanced traceability, and demonstrable quality assurance that meets the demanding requirements of customers in the oil and gas, chemical processing, nuclear power, and other high-integrity industries.