Active Thermography for NDT — Detect Porosity & Lack of Fusion
Active thermography is a thermography NDT method that uses controlled heat stimulation and an IR camera to reveal subsurface weld defects (porosity, lack of fusion, inclusions) and let AI score every seam in-line. Deploy thermographic testing (TT) to generate traceable evidence for ISO 17635 / ISO 3834 workflows, reduce rework, and improve first‑pass yield.
See thermographic NDT in action
- Detect porosity, lack of fusion, and thermal anomalies during the weld cycle
- Automatic pass/fail with ISO 17635 / ISO 3834 evidence packs
- API-ready outputs for QMS / MES traceability
Stop missing subsurface issues before they become scrap
Detect what vision can’t
Stimulated thermal response shows porosity, voids, and lack of fusion even on clean beads. Operators get a red/green verdict in seconds.
Evidence for auditors
Each weld is logged with temperature profiles, defect flags, and operator ID—ready for ISO 3834, EN 1090, or customer PPAP.
Fewer restarts, less downtime
Inline alerts catch drift before it creates scrap. Plants report fewer stoppages and faster parameter corrections.
Estimate rework savings from inline thermography
If you’re comparing approaches, see the full weld monitoring system overview. For the passive in-process method and the downloadable guide, see thermography NDT testing.
Results
Note: this is a simplified model for scrap/rework cost. Many lines also save on audit time (ISO 17635 evidence) and downtime.
Download the active thermography (TT) PDF
PDF preview
Preview excerpt (ungated): how pulsed vs lock‑in excitation changes detection depth, what “good” thermal response looks like, and a practical checklist to package TT evidence for audits.
What you’ll get
- Thermographic testing (TT) concepts for weld inspection
- Pulsed / lock‑in excitation approaches and practical notes
- Defect patterns: porosity, lack of fusion, overheating / drift
- How to package evidence for audits and customer requirements
Prefer video?
Watch the short demo, then ask for a tailored setup recommendation.
Inline Weld Inspection: How Active Thermography Fits an NDT Plan
Pulsed / flash thermography
Short heat excitation + transient response analysis. Useful for fast scans and near‑surface discontinuities, and for repeatable inspections on production lines.
Lock‑in thermography
Periodic stimulation + phase/amplitude mapping. Higher sensitivity to deeper defects and more robust results under variable surface emissivity.
From detection to evidence
Therness combines TT data with AI scoring to generate traceable records (thermal frames, verdicts, timestamps) ready for audits and customer submissions.
The thermal cameras behind it: the cylindrical HeatCam IR-C for fixed cells and pipe welding, and the compact HeatCam IR-S for embedded WAAM and robotic heads. Prefer a deeper walkthrough? Read infrared thermography in welding or watch the real-time thermal imaging demo.
Active thermography + AI + QMS integration
HeatCore Basic
Entry-level thermal monitoring with statistical process control. Live view, recording, and traceability for operators stepping into intelligent weld monitoring.
- Industrial Panel PC with operator console
- Real-time SPC analysis at 60 Hz
- CSV export and trend analytics per job
HeatCore AI
Advanced thermal monitoring with deep-learning anomaly detection and Kaizen reports. Inline active thermography camera with automated defect detection and operator guidance.
- Proprietary deep-learning weld defect classification
- Adaptive statistical pattern recognition
- Edge architecture, no cloud dependency
PoolDrop
High-speed visual module of the HeatCore platform. 480 fps acquisition with laser-safe illumination — captures pulsed-MIG transients and surface defects in real time.
- Up to 480 fps capture
- Laser-safe integrated illumination
- USB 3.0 plug-and-play with HeatCore servers
Ready for ISO 17635, ISO 3834, EN 1090, ASME
Acceptance criteria baked in
Select the weld process and class; the system scores defects automatically and logs pass/fail with operator notes.
Traceable by design
Each weld stores images, temperature curves, and timestamps. Export to QMS, CAPA, or supplier portals.
PDF evidence on demand
Generate auditor-ready PDFs natively, or integrate with your existing QMS via API for automatic filing.
Monitoring WAAM / DED builds with thermal data
In‑situ monitoring for WAAM
Track heat input uniformity, cooling profiles, and hotspots that correlate with porosity and lack of fusion on additive cells.
Explore WAAM monitoring →Watch WAAM monitoring clips
Short application videos show thermal visualization and AI scoring for titanium WAAM.
WAAM thermal monitoring video →Read the WAAM guide
Understand WAAM fundamentals, titanium microstructure, and why monitoring is essential for qualification.
WAAM titanium guide →Active thermography that matches your production
Automotive & EV
Detect porosity on thin-gauge steel and aluminum, with automated PPAP-ready evidence.
Pressure vessels
Monitor root and cap passes, flag lack of fusion early, and export to ASME documentation.
Robotic cells
Integrate with robot controllers for inline go/no-go decisions and automatic parameter adjustments.
Manual welding
Provide instant operator feedback and reduce rework on repair welds and short runs.
Talk to sales about active thermography (TT) for welding
Tell us your weld process, material, joint type, and standards. We’ll reply within 24 hours with the best-fit monitoring approach.
Ready to deploy active thermography in your NDT plan?
Download the white paper or book a live demo to see how Therness AI grades every seam and sends proof straight to your QMS.
Active thermography NDT FAQs
How does active thermography improve NDT for welds?
Active thermography stimulates the weld with controlled heat and captures the thermal response to reveal porosity, lack of fusion, or inclusions that visual inspection misses. Combined with Therness AI, it flags anomalies in real time and logs ISO 17635 evidence automatically.
What defects can thermographic testing (TT) detect in welding?
Thermographic testing (TT) can help identify thermal patterns correlated with porosity, lack of fusion, inclusions, overheating, and process drift. The detectable depth depends on material, geometry, excitation method (pulsed/lock-in), and setup.
What standards apply to thermographic testing (TT)?
Thermographic testing is covered by EN 16714 (thermographic testing) and personnel certification for TT is included in ISO 9712. For weld inspection and quality documentation, thermography is typically integrated into broader welding/NDT workflows such as ISO 17635 and ISO 3834.
Can active thermography support ISO 3834 or EN 1090 compliance?
Yes. Acceptance criteria are pre-set for ISO 17635, ISO 3834, and EN 1090. Each weld generates a traceable record and pass/fail status that can feed your QMS or customer PPAP package.
Can thermography be used for WAAM / DED process monitoring?
Yes. In WAAM/DED, thermal monitoring helps track melt pool behavior, heat distribution, and interpass temperature—supporting layer-by-layer quality assurance and early detection of parameter drift.
