From the flicker of the first electric arc in the 1800s to today’s intelligent welding cobots, the history of MIG (Metal Inert Gas) welding is a testament to human ingenuity, precision, and progress. Whether you’re a seasoned fabricator or just curious about how modern welds are made, you’ll find something to spark your interest here.
1800 – The Birth of Arc Welding
In 1800, Sir Humphry Davy used a voltaic pile and two carbon electrodes to create the first electric arc. Though it was initially a scientific novelty, the ability to generate intense, focused heat with electricity laid the foundation for all arc-based welding methods.
1881 – Consumable Electrodes Enter the Field
Fast forward to the late 19th century: Charles Coffin and Nikolay Slavyanov patented the first metal-arc welding techniques. Unlike carbon arcs, their methods used consumable metal electrodes, allowing for simultaneous arc creation and filler deposition. This leap made welding far more efficient and structurally sound.
1920s – Continuous Wire Feed Systems
The early 20th century saw General Electric and others developing continuous wire-feed systems. In 1920, P.O. Nobel patented a rudimentary feeder that adjusted wire speed based on arc voltage. The concept was revolutionary, but without shielding gas, welds were prone to oxidation and brittleness.
1930s – 1940s – Shielding Gas vs. Flux
By the 1930s, welders battled oxidation with two shielding methods:
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- Submerged Arc Welding (SAW): Used powdered flux to cover the arc, enhancing deposition but limiting orientation.
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- Gas Tungsten Arc Welding (GTAW): Used inert gases like argon and helium for cleaner results.
These developments would converge in what we now call MIG welding.
1948 – MIG Welding Is Born
In 1948, the Battelle Memorial Institute developed a process that combined continuous wire feed with an inert argon gas shield. This allowed for stable, clean spray-transfer welding—ideal for aluminum and other non-ferrous metals. MIG welding as we know it had arrived.
1953 – Cost-Cutting with CO₂
Argon was expensive, especially for steelwork. Enter CO₂, which offered a hotter arc and lower cost. Although this came with increased spatter and bead roughness, it made MIG viable for large-scale industries like shipbuilding and bridge construction.
The Affect of Mixing Welding Gasses – Source: https://www.mig-welding.co.uk/forum/threads/custom-gas-mix.1944/
1950s – Short-Circuit Transfer Takes Over
Engineers soon developed short-circuit transfer (aka “dip transfer”). Fine wires made contact with the base metal several hundred times per second, depositing small, controlled droplets. The result: low-heat, precision welds for thin metals and all-position welding.
Different Welding Transfer Methods – Source: https://www.hobartbrothers.com/resources/technical-articles/welding-transfer-modes-tips-for-achieving-the-best-results/
1960s – Refinements and Pulsed-Spray
By the 1960s, adding small amounts of oxygen or CO₂ to shielding gas helped smooth spray transfer. Then came pulsed-spray welding, which alternated high and low current to control heat and spatter. Perfect for medium-thickness materials and excellent bead quality.
The different stages of metal transfer in pulsed-spay welding – Source: https://www.weldclass.com.au/blog/94-what-is-a-pulse-mig-a-how-why-guide-to-pulse-mig-welding
1970s – 1990s – The Digital Era: Synergic Control and STT
Electronics entered the scene in the 70s. Solid-state controls enabled “synergic” machines—adjust one setting, and the machine handles the rest. In the 1990s, Surface-Tension Transfer (STT) by Lincoln Electric revolutionized low-spatter short-circuit welding, ideal for high-spec applications.
1980s – 2000s – Robotic Welding Takes Over
Industrial robots automated MIG welding in large factories, especially automotive. While incredibly fast and repeatable, these systems required safety cages and complex programming—barriers that kept small shops from reaping the benefits.
Industrial Welding Robots – Source: https://www.kemppi.com/en/blogs/power-and-performance-for-robotic-welding
2000s – Now – The Rise of Cobots
Collaborative robots (cobots) flipped the script. These programmable arms could safely work alongside humans, required no fencing, and were controlled with intuitive interfaces. Cobots democratized welding automation for shops of all sizes.
2018 – Now – SwitchWeld Redefines MIG Automation
Today, SwitchWeld leads the charge in accessible welding tech. Their Cobot MIG Cell combines AUBO arms with plug-and-play weld tech. Just guide the torch, tap a few buttons, and let the cobot deliver clean, spec-compliant welds with minimal training or setup.
Final Thoughts: Why It Matters
From early sparks to smart cobots, MIG welding has continually evolved to meet the needs of fabricators. Understanding this history isn’t just about nostalgia—it’s about seeing the innovation that powers the welds of tomorrow.
Explore SwitchWeld today and see how history is helping small shops build a smarter, stronger future.