Nickel mining started in Sudbury, Ontario in 1902, and that year, the International Nickel Company, Ltd. was created by Thompson and John Pierpont Morgan in New York, NY as a joint venture between Canadian Copper Company, Orford Copper Company, and American Nickel Works, with a capitalization of $28 million. In 1905, Monel alloy was discovered by Robert Crooks Stanley (1876-1951) and named for Inco President Ambrose Monell. Meanwhile, the development of austenitic stainless steel was launched by a pair of Krupp engineers known today as AISI Type 304 or simply 18/8, which indicates a nickel content of 8%. This novelty would assure the 20th-century success of the firm.
On 31 October 1928 the Canadian body corporate and its American parent switched roles and the Canadian became the parent. On 1 January 1929 the corporation acquired the British-owned Mond Nickel Company in exchange for treasury shares, to solve the Frood Mine problem. By 1931, Stanley had progressed to President of the firm. Between 1935 and 1939, sales exceeded 200 million pounds annually, which
was more than 80% of world consumption. A significant proportion of these sales found their way to the United States, with other notable markets including the Soviet Union, Great Britain, Japan, and Germany. Approximately 9 percent of company's total sales from 1934 to 1939 were to Nazi Germany, mainly to meet the growing demand of the country's armaments industry.
Stanley's excellent contribution to Inco was his devotion to alloy research, which contributed to the expansion of the market for the base metals it produced. In his first Annual Report in 1922 after becoming President, Stanley informed the shareowners of the new Development and Research Department. At the same time, management told the directors that "we had no market developed [for Monel] which would justify a mill, but we assured them that with a mill we could build a market which would earn the preferred dividend." The directors thereupon invested three quarters of all the liquid resources of the company into the Huntington WV plant to satisfy a market which management had just said did not exist. The Monel alloy family grew into more than a dozen members, and Duranickel, Permanickel, Ni-span-C, Inconel X and Nimonic were all discovered under his watch, most at his Huntington Works baby.
JL Agnew originated the Geology Department of the firm, as a result of his investigations into the Frood Mine problem, which precipitated the 1929 merger with the Mond Company. This department was instrumental in the Manitoba discovery 25 years after his death.
On 1 April 1929 the Ontario Refining Company (ORC) was formed in a joint venture between the American Metal Company, the Consolidated Mining and Smelting Company, Inco and Ventures Limited (which was the parent of Falconbridge Limited). The first and third named companies had each a 42% share. By June 1935 the ORC, which worked at the electrolysis of copper, was a wholly owned subsidiary of Inco. The Inco Triangle, a monthly newsletter for the company, had its first issue of eight pages in September 1936.
In its heyday during the 1950s, Inco produced 85% of the world's nickel supply. In 1956, geologists discovered the Thompson, Manitoba ore body and named it for Inco Chairman John Fairfield Thompson. The first Canadian-born President of Inco, who held the office between 1960 and 1966, was named James Roycroft Gordon.
The year 1969 saw a bloody four-month long strike at Inco's Sudbury operations, and the firm's share price was cut in half.
In 1972, it was decided by Chairman L. Edward Grubb, ostensibly to pacify the labour unions, to move the head office from New York to Toronto where it resided in the Toronto Dominion Centre. Also in 1972 the Inco Superstack was built in Sudbury; at the time senior technical staff like Paul Queneau thought this would solve the SO2 acid rain pollution problem. And in 1972, the Soroko project in Indonesia was begun together with involvement from six Japanese firms who together held a 40% share in the project.
In July 1974 Chairman L. Edward Grubb decided to diversify Inco's holdings and make the first ever hostile takeover bid for Philadelphia-based Electric Storage Battery Company (ESB), aided by Morgan Stanley. United Aircraft Corporation entered as white knight and served to increase Grubb's bid to a 110 percent premium above the pretakeover price. The merger was characterized as a "major blunder" and by December 1981 Inco was looking to exit the battery business. In February 1983 Inco sold most of its holdings in Exide and exited the battery business. ESB manufactured amongst other products the Ray-O-Vac battery.
Inco also built and operated a facility that included a research center overlooking Blue Lake in New York's Sterling Forest area. That site was sold in the 1980s.
During the first half of the 1980s Inco bled a lot of red ink, "which caused the elimination during the five years from 1980 of more than 12,000 jobs worldwide, or 35 percent of its work force, including more than 6,000 jobs in Canada." It then produced one-third of the world's nickel. Charles F. Baird was the chairman and CEO. By 1985 Inco (Alloy Products) division included: Doncasters Blaenavon Ltd Special Alloy Products Division, Doncasters Monk Bridge Ltd, Doncasters Sheffield Ltd, Doncasters Moorside Ltd, Beaufort Engineering Ltd, Whittingham and Porter Ltd, I.A.P.L. Technology Centre and Inco Selective Surfaces Ltd.
The SO2 abatement project (SOAP) instigated a $600 million clean-sheet recomposition of the smelter plant that allowed INCO to capture 90% of their emissions, and commercialize sulfuric acid.
In February 2001, nine-year CEO Michael Sopko stepped down while he announced a $400 million profit. He was replaced by New York lawyer Scott Hand.
In 2002, the VBM purchase was regarded as a "costly blunder... when the company had to write down a third of the value of the $4-billion acquisition only six years after the purchase," but in early 2004 that did not prevent Hand from making a bid for Noranda and Falconbridge, both of which were at the time owned by Brascan, who then declined the Inco offer. The bait in the water attracted Mick Davis and Roger Agnelli. Hand was not deterred from his takeover madness and went to Australia to try his luck in the Western Mining sweepstakes, where he was outbid by XStrata's offer of US$5.7 billion and the ultimately successful BHP Billiton bid of $7.3 billion. Not last in the waters was Teck Cominco's Don Lindsay, a product of CIBC World Markets and who had advised Falconbridge in their failed acquisition of VBM.
On October 11, 2005, Inco's CEO Scott Hand announced a friendly takeover bid to buy out the operations of longtime rival Falconbridge for $12 billion. If approved, the deal would have made Inco the world's largest producer of nickel. Davis's Xstrata (which already owned ~20% of Falconbridge shares) subsequently submitted a hostile takeover bid for Falconbridge, resulting in a bidding war between Inco and Xstrata. The Xstrata bid was successful, but not before Falconbridge employed a poison pill to delay the acquisition, raising its share price from $28 to $62.50 in the meantime.
In May 2010, Vale changed the name of Vale-Inco to simply Vale, stating the change is "a milestone that aligns it more fully with other Vale operations worldwide and reflects its position as part of the world's second largest mining company".
In 2015, Vale was said to be exploring an IPO of its base metals unit for $30–35 billion, in order to lighten its debt load.
Vale spun out its metals business as a separate ringfenced entity headquartered in Toronto, with an independent board chaired by Cutifani. That process completed in July 2023. The unit was then one of the world's largest producers of nickel, copper, and cobalt, and had operations across the globe. The parent company's chief executive Eduardo Bartolomeo stated that Cutifani could help the division explore a future “liquidity event”. In early 2023, the parent company earned 80% of its profits in its South American iron mines, and the balance from its Base Metals group.
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Thompson, John Fairfield; Beasley, Norman (1960). For the Years to Come: A Story of International Nickel of Canada. Toronto: Longmans, Green & Co.
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