Active Thermography for NDT — Detect Porosity & Lack of Fusion
Deploy thermographic testing (TT) to reveal subsurface weld defects (porosity, lack of fusion, inclusions) and let AI score every seam in-line. 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
Active thermography highlights defects that visual inspection or post-process checks miss. Therness adds AI grading so every weld is scored instantly.
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
Use this quick estimator to translate defect reduction into annual savings. For a deeper breakdown (downtime, scrap, payback), see the full ROI guide.
If you’re comparing approaches, see the full weld monitoring system overview.
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
Get the full guide: TT fundamentals, pulsed vs lock‑in setup notes, weld defect examples, and reporting guidance for ISO 17635 / ISO 3834 workflows.
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.
Watch the demo video →Inline Weld Inspection: How Active Thermography Fits an NDT Plan
Active thermography uses controlled heat stimulation and an IR camera to measure thermal response—helping locate defects and quantify process drift. Thermographic testing is standardized in EN 16714 and personnel certification is covered by ISO 9712 (TT).
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.
Prefer a deeper walkthrough? Read infrared thermography in welding or watch the real-time thermal imaging demo.
Active thermography + AI + QMS integration
Deploy as a self-contained thermal system or connect to multi-modal monitoring when you need vision and acoustics, too.
HeatCore AI™
Inline active thermography camera with automated defect detection and operator guidance.
- Configurable excitation for steel, aluminum, and exotic alloys
- Automatic pass/fail by joint type and WPS
- Edge and cloud reporting for multi-cell teams
DuoSense AI™
Add visual and acoustic channels when surface quality and arc stability are critical.
- Detect undercut, overlap, and spatter alongside thermal faults
- Audio analytics flag arc instability before defects form
- Unified reports for quality and maintenance teams
OmniSense AI‑X™
Enterprise platform combining thermal, visual, and audio to supervise multiple welding cells with centralized analytics.
- 99%+ detection accuracy with AI-assisted review
- APIs to feed CAPA, SPC, and supplier scorecards
- Fleet dashboards for multi-plant oversight
Ready for ISO 17635, ISO 3834, EN 1090, ASME
Pre-set acceptance criteria and templated reports help you satisfy auditors and customers without manual paperwork.
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 or integrate with QMS Copilot for automatic filing.
Monitoring WAAM / DED builds with thermal data
Wire Arc Additive Manufacturing (WAAM) depends on stable thermal history, melt pool control, and interpass temperature. Thermography helps you spot drift early and document layer‑by‑layer quality.
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
From automotive frames to pressure vessels, we tune excitation profiles and AI thresholds to your standards.
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.