Die hammer forging is a critical manufacturing process used to produce high-strength components such as railway axles, drive shafts, and heavy-duty mechanical parts. Operating under extreme temperatures and harsh environmental conditions, this process demands precise thermal control to ensure consistent product quality and reliable equipment performance.
As production speeds increase and quality requirements become more stringent, traditional temperature measurement methods are no longer sufficient. Infrared (IR) temperature monitoring provides a modern, efficient solution—enabling continuous, real-time, non-contact measurement throughout the forging process.
Temperature Control as a Critical Success Factor
In die hammer forging, metal workpieces are heated to very high temperatures—typically above 900°C—before being shaped using powerful hydraulic or counterblow hammers. At these temperatures, the material becomes ductile enough to be formed without cracking.
Equally important is the temperature of the forging tools. Hammers and dies must be preheated to prevent thermal shock and ensure proper interaction with the workpiece.
Even small temperature deviations can have serious consequences:
- Too low temperature → insufficient deformation, structural defects, need for reheating
- Too high temperature → material degradation, reduced strength, tool damage
- Uncontrolled cooling → formation of thermal gradients and internal stresses
Maintaining a stable and uniform temperature is therefore essential for both product integrity and process efficiency.
Challenges in Temperature Measurement
Accurate temperature measurement in die hammer forging is particularly difficult due to several factors:
- rapid temperature changes during handling and deformation
- formation of oxide scale on the metal surface
- extreme environmental conditions (heat, dust, smoke, vibration)
- limited accessibility during high-speed operations
The oxide layer that forms during forging is especially problematic, as it alters the emissivity of the surface and leads to inaccurate readings when using conventional measurement methods.
Handheld devices, such as portable pyrometers, are not suitable for continuous monitoring and cannot reliably capture fast temperature fluctuations. This results in incomplete data and increases the risk of defects and process instability.
Infrared Technology as a Solution
Infrared temperature measurement overcomes these challenges by providing continuous, non-contact monitoring of both the workpiece and the forging tools.
IR systems deliver:
- real-time temperature data for immediate process control
- accurate measurements despite oxidation, smoke, and dust
- full-surface thermal analysis, not just single-point readings
- reliable operation in extreme industrial environments
This enables manufacturers to maintain optimal temperature conditions throughout the entire forging cycle.
Optimizing Forging with SWIR Cameras and Pyrometers
A combination of short-wave infrared (SWIR) cameras and infrared pyrometers ensures complete thermal control of the forging process.
SWIR Thermal Cameras (Xi 1M & PI 1M)
SWIR cameras operate in the spectral range of 0.85–1.1 µm, making them ideal for measuring hot metals with high accuracy, even when emissivity varies.
Xi 1M camera:
- measurement range: 450°C to 1800°C
- resolution: 396 × 300 pixels
- real-time hotspot detection
- autonomous operation with analog output
PI 1M camera:
- high resolution up to 764 × 480 pixels
- frame rates up to 1 kHz
- precise monitoring of fast-changing temperatures
These cameras allow continuous monitoring of the entire workpiece surface, ensuring that no critical temperature deviations go unnoticed.
Infrared Pyrometers for Targeted Measurements
For precise point measurements, infrared pyrometers play a key role:
CTratio 1M:
- measurement range: 450°C to 3000°C
- fiber-optic design for harsh environments
- two-color ratio technology for reliable readings in smoke and dust
CSvision:
- motorized focus and video sighting
- measurement range: 550°C to 3000°C
- ideal for extreme industrial applications
CT LT:
- measurement range: -50°C to 975°C
- suitable for monitoring cooling stages
These devices ensure accurate monitoring of critical components, including forging tools and specific process zones.
Reliable Integration in Harsh Environments
Infrared systems are designed for seamless integration into industrial processes:
- direct connection to PLC systems
- real-time data transmission and control
- automated process adjustments
To withstand extreme conditions, systems can be equipped with:
- water-cooled protective housings
- air purge systems to protect optics
- vibration-resistant mounting solutions
This ensures uninterrupted operation and consistent measurement accuracy.
Benefits of Infrared Temperature Monitoring
Enhanced Product Quality
- consistent forging temperatures
- reduced defects and scrap
- improved material properties
Reduced Tool Wear and Downtime
- prevention of overheating
- extended tool lifespan
- fewer maintenance interruptions
Improved Process Efficiency
- real-time monitoring and control
- reduced reliance on manual measurements
- optimized production flow
Reliable Performance in Harsh Conditions
- accurate readings despite dust, smoke, and oxidation
- stable operation at high temperatures
Lower Costs and Increased Productivity
- reduced material waste
- minimized rework
- higher overall equipment efficiency
As die hammer forging processes evolve, the need for precise and reliable temperature monitoring becomes increasingly important.
Infrared technology provides a powerful solution by enabling continuous, accurate, and real-time temperature control across the entire process. By eliminating the limitations of traditional measurement methods, IR systems help manufacturers improve quality, reduce costs, and enhance operational efficiency.
Implementing infrared temperature monitoring is no longer optional—it is a strategic step toward modern, high-performance forging operations.
