Wire stick-out refers to the portion of the unmelted wire coming out from the contact tip to the arc.
The length of the wire stick-out affects several aspects of the welding process, including arc stability, heat input, and weld penetration.
The ideal wire stick-out length varies depending on the welding process and the material being used.
Weld process considerations
- In Standard GMAW processes, 10 to 15 mm (3/8" to 5/8") are typically used.
- For Pulse GMAW processes, 12 to 20 mm (1/2" to 3/4") are typically used. The stick-out range is slightly longer than conventional GMAW to accommodate the pulsed arc.
Material considerations
- For thin materials, stick-out should be kept shorter to avoid overheating and excessive burn-through.
- For thicker materials, a slightly longer stick-out can help reduce heat input while still achieving good penetration.