What is Electrical Stick-Out in Welding?

The electrical stick-out is the distance from the contact tip to the un-melted electrode end. Sometimes called the “amount of wire in resistance”. This distance influences melt-off rate, penetration, and weld bead shape.

Electrical stick-out can be measured with a variety of devices including calipers, rulers, or a tape measure.
The most accurate method is to use an optical microscope equipped with a reticle eyepiece.
For best results, the microscope should have at least 100x magnification.

In any welding process using a solid or flux cored wire, the electrical stick-out is an important parameter that must be controlled. Too much stick-out will result in poor weld quality, while too little stick-out will cause the weld to be under-penetrated.

The proper amount of electrical stick-out can be found in the welding procedure specification (WPS) for the particular welding process being used. For example, for the gas metal arc welding (GMAW) process, the recommended range of electrical stick-out is 1/8 to 3/16 inches.

When measuring electrical stick-out, it is important to hold the electrode at a 90-degree angle to the workpiece surface. The measuring device should also be perpendicular to the workpiece surface.

How does stick out affect weld?

Stick out has a large effect on the penetration of the weld.

The longer the stick out, the more heat is transferred to the workpiece. This results in more penetration but can also cause the weld to be too deep.
Shorter stick-out lengths result in less penetration. This can cause shallower welds that are not as strong.

Why is correct wire stick out important?

The correct wire stick-out is important because it helps to ensure that the weld has the proper penetration. If the weld does not have enough penetration, it will be weaker. If the weld has too much penetration, it can cause the workpiece to warp or distort.

Which voltage measurement is the most critical to ensuring weld consistency?

There is no definitive answer to this question as it depends on the welding process being used. However, some experts believe that voltage is the most critical measurement when it comes to ensuring weld consistency. Others believe that amperage is more important. Ultimately, it is up to the welder to experiment with different settings to find what works best for them.