Resistance projection welding is a non-polluting mechanized process used to obtain an assembly between similar or dissimilar metallic materials. The main advantages of this welding process are the possibility to achieve many different welded points at the same time and the long life of the electrodes compared to the spot-welding process. The paper analyses the effects of thin aluminium coating existing on mild steel parts of on the correct formation of welding points when assembling moulds for the manufacture of baking bread. From optical and electron microscopy analyses it resulted that some adjacent welded points show an interrupted fusion line, sprinkled with elongated islands of aluminium-rich compounds. The paper presents the effect of changing the values ​​of the welding parameters on the weld spot size, in correlation with the Al-rich inclusions that appear on the weld fusion zone. The best results have been obtained when the welding parameters values were the follows: electrode pressure of 2.6 bar, welding power of 19.18kVA and welding time of 7ms. The problems that occur when electric resistance welding of parts with aluminium coating have been highlighted, being useful for specialists who make products using this welding process.

Today’s hydroprocessing reactor manufacturers use 2¼Cr–1Mo–¼V steel to build lighter reactors than conventional Cr-Mo reactors. Manufacturing even lighter hydroprocessing reactors has been enabled with the introduction of the new ASME Section VIII Division 2 Code, initially released in 2007. The higher allowable stresses in the new Division 2 for these Vanadium-modified steels permits even lighter reactors to be built while maintaining suitable design margins. The new Division 2 Code requires additional engineering to ensure safe design. One of the challenges the engineer is faced with, is preparation of the User’s Design Specification (UDS) including new and more stringent requirements for fatigue evaluation. As the operating temperature of the rector is higher than 371°C, engineers have to evaluate the fatigue life of the reactor in accordance with Code Case 2605 (CC2605). CC2605 requires inelastic analysis and evaluation effects of creep. Vanadium-modified reactors require additional care during fabrication to prevent higher hardness around weld areas, reheat cracking, and reduced toughness at lower temperatures in the “as welded” condition. This paper provide guidance for the preparation of an ASME Section VIII Division 2 User’s Design Specification including process descriptions of all the cycles expected for the life of the rector and analysis requested by CC2605. An example of such an analysis, including finite element analysis results, is provided in this paper. Requirements to provide the material specification is also discussed with an emphasis on prevention of reheat cracking, hardenability, and temper and hydrogen embitterment.