Considering the previous focus on the limitations of deep thermocouple repair in hot runner injection molding scenarios-where it's only applicable to specific situations where the thermocouple wires are not severely aged, and the repaired accuracy cannot fully restore the original factory grade-the mainstream deep thermocouple repair processes are as follows:
Inert Gas Protected Thermocouple Welding Process: In an argon-protected chamber, a miniature spot welder precisely welds the broken thermocouple wire, avoiding high-temperature oxidation of the weld joint. After repair, annealing is required to stabilize thermoelectric characteristics. This process is suitable for fault scenarios involving partial wire breakage.
Sheath Oxide Layer Grinding and Resealing Process: The slightly oxidized outer sheath is ground off, a new high-temperature resistant stainless steel sheath is fitted, filled with magnesium oxide insulating powder, and then sealed to restore the probe's protective performance.
Wire Aging Annealing Regeneration Process: The aged and drifting thermocouple is placed in an annealing furnace and held at a constant temperature of 800~1000℃ for several hours to eliminate internal stress in the wires, correct thermoelectric characteristic drift, and restore basic temperature measurement accuracy.
Cold Junction Compensation Calibration Correction Process: For thermocouples with minor, fixed deviations after repair, the overall temperature measurement deviation is corrected to within the industrial acceptable range by fine-tuning the cold junction compensation parameters of the temperature control system.
These processes only allow repaired thermocouples to meet short-term emergency use standards and cannot fully restore the long-term stability of brand-new components. They are not recommended for use in high-precision mass production of core temperature control points.
