Die hammer forging is a demanding industrial process where precise temperature control of both the workpiece and tooling is essential. Any deviation from optimal temperature conditions can lead to product defects, accelerated tool wear, and costly production interruptions.

As forging environments become more complex and production speeds increase, traditional temperature measurement methods struggle to keep up. Infrared (IR) technology provides a modern, reliable solution by enabling continuous, real-time, non-contact temperature monitoring throughout the entire forging process.

The Challenge: Accurate Temperature Control in Harsh Conditions

In die hammer forging, metal workpieces are heated to extremely high temperatures before being shaped using powerful hydraulic or counterblow hammers. This process is widely used to manufacture critical components such as railway axles, drive shafts, and heavy-duty mechanical parts.

Maintaining precise temperature control is crucial for both:

  • the workpiece, to ensure proper deformation and metallurgical properties
  • the forging tools, to prevent thermal shock and damage

However, several factors complicate temperature monitoring:

  • rapid cooling of the workpiece during handling and forging
  • formation of oxide scale on the surface
  • extreme environmental conditions (heat, dust, smoke, vibrations)
  • limited accessibility during high-speed operations

Incorrect temperature control leads to serious issues:

  • underheating → poor material deformation and structural defects
  • overheating → material degradation and tool damage
  • inaccurate readings → process instability and increased scrap

Manual measurement methods are not only inefficient but often unreliable under these conditions.

Limitations of Conventional Measurement Methods

Traditional tools such as handheld pyrometers are widely used but present major drawbacks:

  • provide only intermittent measurements
  • depend heavily on operator accuracy
  • fail to detect rapid temperature changes
  • are affected by oxide layers on metal surfaces
  • are impractical in hazardous forging environments

As a result, critical temperature variations often go unnoticed, reducing product quality and increasing production costs.

Infrared Monitoring as a Solution

Infrared pyrometers and short-wave infrared (SWIR) thermal cameras offer a powerful alternative by delivering continuous, real-time temperature data without physical contact.

Key advantages of IR monitoring:

  • accurate measurement despite oxidation, smoke, and dust
  • real-time feedback for dynamic process adjustments
  • monitoring of both surface and critical hotspot temperatures
  • reliable operation in extreme industrial environments

This enables manufacturers to maintain optimal forging temperatures throughout the entire process.

Optimizing Die Hammer Forging with IR Technology

A combination of infrared pyrometers and SWIR thermal cameras ensures comprehensive temperature control across all stages of forging.

SWIR Thermal Cameras (Xi 1M & PI 1M)

Short-wave infrared cameras are ideal for hot metal measurement due to their spectral range of 0.85–1.1 µm, which provides accurate readings even when emissivity varies.

Xi 1M infrared camera:

  • measurement range: 450°C to 1800°C
  • resolution: 396 × 300 pixels
  • real-time hotspot detection
  • autonomous operation with analog output

PI 1M infrared camera:

  • high resolution: up to 764 × 480 pixels
  • frame rates up to 1 kHz for fast processes
  • precise monitoring of rapidly changing temperatures

These cameras enable full-surface temperature monitoring, ensuring no critical variations go undetected.

Infrared Pyrometers for Point Measurements

For precise point-based measurements, infrared pyrometers provide essential control:

CTratio 1M pyrometer:

  • measurement range: 450°C to 3000°C
  • fiber-optic design for harsh environments
  • two-color ratio measurement for accuracy in smoke and dust

CSvision pyrometer:

  • motorized focus and video alignment
  • measurement range: 550°C to 3000°C
  • ideal for extreme industrial conditions

CT LT pyrometer:

  • range: -50°C to 975°C
  • suitable for monitoring cooling stages and auxiliary processes

These devices ensure precise monitoring of both the workpiece and forging tools.

Seamless Integration and Industrial Reliability

All infrared devices can be integrated directly into existing control systems, enabling:

  • real-time data transmission to PLC systems
  • automated process adjustments
  • continuous temperature tracking

To ensure reliability in harsh environments, systems are equipped with:

  • water-cooled protective housings
  • air purge systems for lens protection
  • robust, vibration-resistant designs

This guarantees uninterrupted operation even in extreme forging conditions.

Benefits of Infrared-Based Temperature Monitoring

Improved Product Quality

  • consistent forging temperatures
  • reduced defects and scrap
  • elimination of thermal inconsistencies

Reduced Tool Wear and Downtime

  • prevention of overheating damage
  • extended tool lifespan
  • fewer unplanned maintenance events

Higher Process Efficiency

  • real-time monitoring and control
  • reduced reliance on manual measurements
  • optimized production flow

Reliable Operation in Harsh Environments

  • accurate readings despite dust, smoke, and oxidation
  • stable performance under extreme heat and vibration

Lower Costs and Increased Productivity

  • reduced material waste
  • minimized rework
  • improved overall equipment efficiency

As die hammer forging processes become more advanced and production demands continue to grow, precise temperature monitoring is essential for maintaining quality, efficiency, and safety.

Infrared technology transforms forging operations by providing continuous, accurate temperature data and enabling real-time process control. By overcoming the limitations of traditional measurement methods, IR solutions help manufacturers:

  • enhance product quality
  • reduce downtime and maintenance costs
  • improve process stability
  • increase production efficiency

Implementing infrared temperature monitoring is no longer just a technological upgrade—it is a strategic investment in modern, high-performance forging operations.