Alessi 9090: Weld
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In spot-welding, the heat is generated by electric resistance: Copper electrodes pass a current between sheets of steel and the steel becomes so hot that a spot melts between the sheets to fasten them together. The challenge of the 9090 is precision. “Sapper invented a new closure,” Alessi remembers, “which can be done with one hand—–the handle on the top half swings down to clip over the lower boiler, holding it all together.”

A worker at Alessi examines the two steel fittings that were spot-welded to the boiler body of the 9090. Tight tolerances are required to ensure that this closure forms an adequate seal with the upper container, if it doesn't, the unit will not function properly.

Two bent-steel fittings spot-welded onto the boiler body form the seal. A jig helps to line them up, and the worker presses a pedal, which clamps the electrodes. “This closure has tight tolerances,” explains Alliata. “Otherwise the seal will be inadequate and the consequences are drastic.”

After the latching components of the boiler body are precisely aligned in a jig, a technician at Alessi spot-welds the pieces together.

Metal components of the 9090 are fused together using a tungsten inert gas (TIG) welder.

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