Otis Singleton
The history of welding is a long and fascinating one, with the practice evolving over thousands of years. While the exact date of the invention of the first electric welder is hard to pinpoint, it is known that electric resistance welding was developed in the final decades of the 19th century, with the first patents going to Elihu Thomson in 1885. However, it wasn't until electricity became widely available in the early 20th century that modern electric welding took off. During this time, the world wars drove the demand for reliable and inexpensive joining methods, leading to the development of several modern welding techniques, including shielded metal arc welding, gas metal arc welding, and submerged arc welding.
| Characteristics | Values |
|---|---|
| Date | 1881-1882 |
| Inventors | Nikolai Benardos and Stanisław Olszewski |
| Type of welding | Electric arc welding |
| Type of electrode | Carbon |
| Other key figures | Humphry Davy, Arthur Percy Strohmenger, Elihu Thomson, C.J. Holslag, P.O. Nobel, Robert Gage, Kumar Patel, Wayne Thomas |
| Subsequent developments | Coated electrodes, automatic welding, MIG welding, plasma arc welding, laser beam welding, explosion welding, friction stir welding |
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What You'll Learn
Electric welding's history
Electric welding has a long and fascinating history, with advancements in technology driving the development of new welding techniques.
The 19th Century:
In the early 1800s, Sir Humphry Davy produced the first short-pulse electric arc by transmitting an electric current through two carbon rods. In 1881-82, Nikolai Benardos and Stanisław Olszewski invented the first electric arc welding method, carbon arc welding, using carbon electrodes. This was followed by the invention of metal electrodes in the late 1800s by Nikolai Slavyanov and C. L. Coffin. Resistance welding was also developed during this century, with the first patents going to Elihu Thomson in 1885. Forge welding, which involved heating and hammering, was the only welding process until the end of the 19th century.
The Early 20th Century:
The 20th century brought rapid developments in welding technology, driven by the demands of World War I and World War II. In 1900, Arthur Percy Strohmenger released the first coated metal electrodes, offering increased arc stability and more consistent welds. Metal electrodes had already been in use for around a decade, but Strohmenger's invention made arc welding a more viable option. Around the same time, acetylene torches were developed, making oxyfuel welding more popular due to its portability and low cost. In 1919, the American Welding Society was founded, and alternating current welding was introduced by C.J. Holslag, although it did not gain popularity until the next decade.
Post-World War II:
After World War II, several modern welding techniques were developed, including manual methods like shielded metal arc welding and semi-automatic and automatic processes such as gas metal arc welding (GMAW), which became commercially available in 1948. In 1920, P.O. Nobel of General Electric invented automatic welding, and in 1941, Ted Nelson invented stud welding for use in shipbuilding.
The Space Age:
The Space Age saw further advancements, with the first patent for plasma arc welding awarded to Robert Gage in 1957. Explosion welding, developed by DuPont in 1962, can bond two metals that cannot be welded by other means. Laser beam welding was born in 1964 with the development of the Co2 laser by Kumar Patel of Bells Labs. Friction Stir Welding (FSW) was invented by Wayne Thomas in 1991.
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Early electric welding methods
The early history of electric welding methods can be traced back to the 19th century with the discovery of the electrical arc in 1800 by Sir Humphry Davy, who formed the first electric arc between two carbon electrodes. This laid the foundation for all subsequent forms of arc welding. However, it was not until the late 19th century that arc welding and oxy-fuel welding emerged as the first welding processes, with electric resistance welding following soon after. Forge welding, which involved heating and hammering to join iron and steel, had been the only welding process for millennia.
In 1888, Russian inventor Nikolay Gavrilovich Slavyanov introduced arc welding with consumable metal electrodes, marking the second form of arc welding invented and the first instance of "stick welding". Slavyanov's technique, which he termed electric casting of metals, led to the development of shielded metal arc welding ("SMAW") with the introduction of coatings on the metal electrode to provide shielding for the molten metal.
The turn of the 20th century brought significant advancements in welding technology. In 1900, Arthur Percy Strohmenger and Oscar Kjellberg introduced the first coated electrodes, improving arc stability and weld consistency. Elihu Thomson, a key figure in the widespread adoption of electricity, invented resistance welding and established Thomson-Houston in 1880 to sell arc lamp systems. By the early 20th century, with electricity becoming more accessible, modern electric welding gained traction.
During the early decades of the 20th century, welding technology progressed rapidly, driven by the demands of World War I and World War II. In 1919, the American Welding Society was founded, and alternating current welding was introduced by C.J. Holslag, although it would take another decade to gain popularity. The 1920s and 1930s witnessed the invention of automatic welding by P.O. Nobel of General Electric, the development of submerged arc welding, and the release of stud welding by Kyle Taylor, which revolutionised shipbuilding and construction.
The space-age further propelled welding innovations, with the first patent for plasma arc welding awarded to Robert Gage of Union Carbide in 1957. This was followed by the invention of laser beam welding by Kumar Patel of Bell Labs in 1964, utilising a CO2 laser.
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Modern electric welding
The founding of the American Welding Society in 1919, along with the introduction of alternating current welding by C.J. Holslag, further advanced the field. However, it was Elihu Thomson's invention of resistance welding and his contributions to electricity accessibility that laid the groundwork for modern electric welding.
Today, welding machines like those offered by ArcCaptain cater to various applications, including repairs, construction, and metalwork. These machines use electricity to generate heat, fusing metal pieces together. They offer control over heat and speed, resulting in strong and clean welds. ArcCaptain's welders are designed for ease of use, featuring digital controls, quick setup, and portability. Their TIG machines, for instance, offer top precision for detailed work.
Different welding processes cater to specific needs. For instance, submerged arc welding, invented in the 1930s, employs a continuously fed metal electrode and granular flux to protect the weld from contamination. Tungsten Inert Gas (TIG) welding, on the other hand, utilizes an inert shielding gas and filler metal to create stronger, higher-quality joints but requires a highly skilled welder due to its complexity.
Modern welding has also witnessed the advent of explosion welding, capable of bonding two incompatible metals, and laser beam welding, which uses a CO2 laser to transmit electrons via light, eliminating the need for a vacuum. Friction Stir Welding (FSW), invented in 1991, and plasma arc welding, patented in 1957, further showcase the diverse array of modern welding techniques.
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Electric welding pioneers
Electric welding is a complex process with a long history of innovations. While it is hard to pinpoint the invention of the first electric welder, there are several pioneers who have made significant contributions to the development of electric welding.
In the early 1800s, Sir Humphry Davy produced the first short-pulse electric arc by transmitting an electric current through two touching carbon rods and pulling them apart. This discovery laid the groundwork for modern welding. Humphry's younger cousin, Edmund Davy, then made an accidental discovery in 1836 when he created potassium chloride, which reacted with water to release acetylene. These separate discoveries provided essential technology for the development of modern welding.
In the late 19th century, inventors Nikolai Benardos and Stanisław Olszewski created the first electric arc welding method, known as carbon arc welding, using carbon electrodes. This was followed by the invention of metal electrodes in the late 1800s by Nikolai Slavyanov and C. L. Coffin. Around 1900, Arthur Percy Strohmenger released the first coated metal electrodes, offering increased arc stability and more consistent welds.
Elihu Thomson played a crucial role in the development of electric welding. He invented resistance welding and received the first patents for it in 1885. Thomson also founded Thomson-Houston in 1880 to sell arc lamp systems, diversifying into other electrical markets and becoming one of the biggest players in the American lighting industry.
The 20th century brought rapid developments in welding technology, driven by the demands of World War I and II. Notable advancements during this period include the invention of automatic welding by P.O. Nobel in 1920, the development of submerged arc welding by the National Tube Works Company in the 1930s, and the invention of stud welding by Ted Nelson in 1941.
The space age brought further innovations, with the first patent for plasma arc welding awarded to Robert Gage in 1957. Explosion welding, a method for bonding two metals that cannot be welded by other means, was developed by DuPont in 1962. Laser beam welding was born in 1964 with Kumar Patel's invention of the Co2 laser. More recently, in 1991, Wayne Thomas invented Friction Stir Welding (FSW).
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Electric welding applications
Electric arc welding is a process that uses electricity to create an intense electric arc between two terminals of an electrical circuit, generating enough heat to melt metal. This process results in the fusion of metals, forming a strong and durable bond. This method of welding has a wide range of applications across various industrial sectors due to its versatility, affordability, and precision.
One of the key applications of electric arc welding is in the construction industry. It plays a crucial role in joining steel structures, frameworks, beams, columns, and prefabricated elements. Electric arc welding is essential for constructing infrastructure such as bridges, buildings, stadiums, and towers. It provides the strength and durability required for these large-scale projects.
In industrial manufacturing, electric arc welding is used to produce a diverse range of machines and equipment. This includes machine tools, industrial robots, tanks, boilers, containers, and machine components. The ability to weld different types and thicknesses of metal makes this process highly valuable in manufacturing.
The automotive industry also relies heavily on electric arc welding for assembling car bodies and metal components. It is used for welding chassis, sheet metal, fenders, and other structural parts. Electric arc welding's precision and reliability make it ideal for the intricate work involved in vehicle assembly.
Additionally, electric arc welding has found applications in aerospace and naval domains. It is often used when quality welds are of utmost importance, such as in aircraft components and marine applications. The stable arc and high-quality welds provided by processes like Gas Tungsten Arc Welding (GTAW) or Tungsten Inert Gas (TIG) welding make them suitable for these critical applications.
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Frequently asked questions
Electric resistance welding was developed in the final decades of the 19th century. Elihu Thomson received the first patents for resistance welding in 1885, and continued to refine the process over the next 15 years.
Elihu Thomson is often credited with inventing the first electric welder. However, Nikolai Benardos and Stanisław Olszewski invented the first electric arc welding method in 1881-82, and Nikolai Slavyanov and C. L. Coffin invented metal electrodes in 1888 and 1890, respectively.
Early electric welders were limited by the lack of widespread access to AC current, and so they ran on large batteries. The first coated electrodes were released in 1900 by Arthur Percy Strohmenger and Oscar Kjellberg, improving the consistency and stability of welds.
The invention of the first electric welder spurred the development of modern welding techniques. Electric welding did not become widespread until electricity was widely available in the early 20th century, and World Wars drove the demand for reliable and inexpensive joining methods.
