---
title: What 2025 Research Told Us About Temperature, Materials, and the Future of Welding
description: Since its release, the Xiris XIR-1800 SWIR thermal camera has become a sought-after tool for welding and metal additive manufacturing (AM) researchers.
image: https://blog.xiris.com/hubfs/Blog%20opengraph-3.png
---

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# What 2025 Research Told Us About Temperature, Materials, and the Future of Welding

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![Dmytro Havrylov](https://blog.xiris.com/hubfs/coil%20joining/user.png)

 Written by Dmytro Havrylov  on December 18, 2025

What do *lunar dust*, *laser heat*, and *metal innovation* have in common? Each pushed the boundaries of what’s possible in manufacturing this year, and each relied on the **Xiris XIR-1800 SWIR thermal camera** to capture it.

Since its release, the **Xiris XIR-1800 SWIR thermal camera** has become a sought-after tool for welding and metal additive manufacturing (AM) researchers. Its ability to measure temperature and cooling rates *in-situ* during AM, welding, and cladding has made it an irreplaceable tool in labs across the globe.

Below, we spotlight several notable publications from this year that leveraged the XIR-1800 to advance materials and manufacturing science.

## **Lunar Regolith for Additive Manufacturing**

*Ana Luisa C. de Lucena et al., Technical University of Denmark *

In a previous blog, we highlighted the work *“[Laser-based directed energy deposition with mullite: a necessary step for lunar regolith printing](https://blog.xiris.com/blog/building-on-the-moon-laser-3d-printing-with-lunar-dust).”* [1] This study explored the feasibility of using lunar regolith—a naturally occurring ceramic material on the Moon’s surface—for **in-situ additive manufacturing on the lunar surface**. The researchers demonstrated that regolith is a viable feedstock for Laser-based DED processes.The XIR-1800 played a crucial role by accurately capturing melt-pool temperatures. The team emphasized that the SWIR technology of Xiris’ thermal camera provides **higher temperature-measurement accuracy** than traditional MWIR and LWIR systems—an essential advantage for extraterrestrial manufacturing research.

| ![1_Lunar](https://blog.xiris.com/hs-fs/hubfs/1_Lunar.png?width=500&height=359&name=1_Lunar.png) Figure 1. Laser DED of lunar regolith as seen by the XIR-1800 thermal camera [1]. |
| --- |

 

 

## **Implementing WAAM in Welding Automation**

*Mikael Fagerström, Lappeenranta–Lahti University of Technology*

In his Master’s thesis, *“Implementing WAAM into Welding Automation and Comparing It with Traditional Manufacturing Methods,” *[2] Mikael Fagerström investigated how Wire-Arc Additive Manufacturing (WAAM) can be integrated into existing production workflows for bearing housings.

An XIR-1800 thermal camera was used to detect weld defects such as [**lack of fusion**](https://blog.xiris.com/welding-defects-guide), providing critical insight into process reliability.

**Congratulations to Mikael on successfully completing his Master’s degree!**

| ![2_WAAM](https://blog.xiris.com/hs-fs/hubfs/2_WAAM.png?width=500&height=470&name=2_WAAM.png) Figure 2. WAAM of bearing housing with weld defects [2]. |
| --- |

 

## **Creep Performance of Haynes 282 Alloy in GMA-DED**

*Sophia Hill, Jamie McIntyre, and Jonah Klemm-Toole, Colorado School of Mines*

In their study, *“Microstructure and Creep Performance of Direct Single-Step Aged Gas Metal Arc Directed Energy Deposition Processed Haynes 282,”* [3] the authors built components for high-temperature power-generation applications using GMA-DED with Haynes 282, a nickel-based alloy known for thermal stability.

The XIR-1800 was employed to monitor **interpass temperatures around 650 °C**. The resulting components showed creep performance intermediate between wrought and cast samples—an encouraging outcome for the use of DED in critical-temperature applications.

In another publication [4], Hill and Klemm-Toole further developed an **analytical model** to predict creep-rupture times for wrought, cast, and DED-fabricated Haynes 282 components.

| ![3_Haynes282](https://blog.xiris.com/hs-fs/hubfs/3_Haynes282.png?width=500&height=300&name=3_Haynes282.png) Figure 3. —EBSD IPF + IQ map of direct-aged GMA-DED Haynes 282 in the middle of the build [3]. |
| --- |

 

## **Laser-Modified Wire Arc Cladding**

*Hana Šebestová et al., Institute of Scientific Instruments of the CAS, Czech Republic*

This compelling work, *“Laser-modified wire arc cladding,”* [5] examined the introduction of supplementary laser heating during wire-arc cladding of Stellite 6. Traditional wire-arc cladding of this alloy is prone to cracking; however, the addition of in-situ laser heating reduced cooling rates by **up to 40%**. This led to **improved bead quality, fewer voids, and higher deposition rates** while maintaining structural integrity.

Cooling rates across temperature intervals of **1200–800 °C**, **1000–800 °C**, and **800–500 °C** were measured using the XIR-1800 SWIR camera.

Find more about our novel Cooling Time Tool for real-time measurements in[*Cooling Time Whitepaper *](https://info.xiris.com/whitepaper-cooling-time-welding-metal-additive-manufacturing)

| ![5_Laser](https://blog.xiris.com/hs-fs/hubfs/5_Laser.png?width=500&height=286&name=5_Laser.png) Figure 4. The temperature field induced by the laser and the temperature profiles on the substrate surface from [5]. |
| --- |

 

## **Automated Monitoring in WAAM**

*Prashant Kumar Chaurasia et al., BAM, Germany*

The study *“Automated in-situ monitoring and analysis of process signatures and build profiles during wire arc directed energy deposition”* [6] focused on improving dimensional consistency in WAAM-fabricated parts. The team investigated optimal step-over ratios between adjacent weld passes.

Using both the **XVC-1000 weld camera** and the **XIR-1800 thermal camera**, they synchronously captured surface profiles, melt-pool images, and top-surface temperature distributions via a centralized real-time monitoring system.  
The collected data contributed to the **Open Source Weld Data** format [7] developed and promoted by the team—an exciting step toward standardized, shareable weld-process data.

| ![6_Monitoring](https://blog.xiris.com/hs-fs/hubfs/6_Monitoring.png?width=1623&height=741&name=6_Monitoring.png) Figure 5. Monitoring framework used in [6]. |
| --- |

 

## **Steel-on-Tungsten Deposition with Intermediate Layers**

*Md Abdul Karim et al., Tennessee Technological University, USA*

In *“Wire-arc directed energy deposition of steel onto tungsten substrate: fabricability and mechanical performance of synergistic structures,”* [8] the authors explored depositing SS316L stainless steel directly onto a tungsten heavy alloy substrate (W7Ni3Fe). While direct deposition proved unsuccessful, the introduction of an intermediate **Inconel IN625** layer enabled successful bonding and acceptable mechanical performance—an important insight for hybrid metal structures.

| ![8_Tungsten](https://blog.xiris.com/hs-fs/hubfs/8_Tungsten.png?width=600&height=485&name=8_Tungsten.png) Figure 6. Residual stress distributions and thermal cycles in W7Ni3Fe/SS316L structures with and without IN625 interlayers from [8]. |
| --- |

 

 

| [![DOWNLOAD WHITEPAPER Using AI and Machine Vision to Improve Welding and Metal Additive Manufacturing Quality  ](https://no-cache.hubspot.com/cta/default/206970/interactive-202007594327.png) ](https://blog.xiris.com/hs/cta/wi/redirect?encryptedPayload=AVxigLLITId1Gtb2ThBpD8aymf7nxyKCU6xStUss%2FOhPUv8HT7Ygh3dWwYYMFWkX5EYbUsLch%2FvmfbuHM0Kz3nMAKfXUQYTqZOCLqLbPcs5acXInxWNZoPO4FP7qGuh957smcODJ86%2F0c%2FkHDcydUfv7CilA780M8xzd%2BMEODyVDeE5D0WP79xBL2fdGoZA0JLKKVh58xT4fqtGb1JnvX9I%3D&webInteractiveContentId=202007594327&portalId=206970) |
| --- |

 

 

#### References

[1] de Lucena, Ana Luisa C., Navid Ranjbar, Saeed Khademzadeh, and Mohamad Bayat. "Laser-based directed energy deposition with mullite: a necessary step for lunar regolith printing." *Materials & Design* (2025): 114605.

[2] Fagerström, Mikael. "Implementing WAAM into welding automation and comparing it with traditional manufacturing methods." (2025).

[3] Hill, Sophia, Jamie McIntyre, and Jonah Klemm-Toole. "Microstructure and Creep Performance of Direct Single-Step Aged Gas Metal Arc Directed Energy Deposition Processed Haynes 282." *Metallurgical and Materials Transactions A* (2025): 1-16.

[4] Hill, Sophia, and Jonah Klemm-Toole. "An Analytical Creep Rupture Time Model for Wrought, Cast, and Gas Metal Arc Directed Energy Deposition Haynes 282." In *Pressure Vessels and Piping Conference*, vol. 89091, p. V05BT06A019. American Society of Mechanical Engineers, 2025.

[5] Šebestová, Hana, Jan Novotný, Jan Štěpán, Ondřej Ambrož, Zdeněk Joska, Jan Gross, and Libor Mrňa. "Laser-modified wire arc cladding." *Available at SSRN 5534586*.

[6] Chaurasia, Prashant Kumar, Çağtay Fabry, Andreas Pittner, Amitava De, and Michael Rethmeier. "Automated in situ monitoring and analysis of process signatures and build profiles during wire arc directed energy deposition." *Progress in Additive Manufacturing* (2025): 1-20.

[7] Fabry, Cagtay, Andreas Pittner, Volker Hirthammer, and Michael Rethmeier. "Recommendations for an Open Science approach to welding process research data." *Welding in the World* 65, no. 9 (2021): 1661-1669.

[8] Karim, Md Abdul, Saiful Islam, Gazi Tanvir, Sainand Jadhav, Young-Min Kim, Yongho Jeon, and Duck Bong Kim. "Wire-arc directed energy deposition of steel onto tungsten substrate: fabricability and mechanical performance of synergistic structures." *Virtual and Physical Prototyping* 20, no. 1 (2025): e2443578.

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| --- |

 

 

 

 

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