[I don't work at Luxonis so don't quote me]
Without the presence of the depth image it is fundamentally very hard to accurately align RGB and IR. This can only be done for a set distance, but not something that works on all distances. I have seen this is done in some examples with OAK thermal image alignment (maybe you can find that).
However, the presence of depth makes it theoretically possible! Although I don't know if the OAK tools support it., let me know if it does.
You could use the IR image to "colourise" the unaligned depth image. Next, align that colourised depth image and success. / Or somehow just apply the depth align transform on the IR image.
I don't think OAK exposes the right functions for this, so you might have to build it yourself together with Claude.