Stick-Out — What It Is and Why It Matters
Stick-out (also called CTWD — Contact Tip to Work Distance, or electrode extension) is the distance between the contact tip inside the MIG gun nozzle and the workpiece surface. This distance directly affects welding performance because the wire heats up resistively as current passes through the exposed length — longer stick-out means more preheating of the wire, which reduces the arc's heat reaching the base metal.
For MIG welding mild steel, the typical recommended stick-out is 3/8" to 1/2" (approximately 10-12mm). Excessive stick-out (over 3/4") causes the wire to preheat too much, reducing penetration and increasing spatter. Insufficient stick-out (under 1/4") increases the risk of the nozzle becoming spattered or blocking gas flow, and can damage the contact tip.
Maintaining consistent stick-out throughout a weld is an important technique skill. As the bead builds up and the welder moves along the joint, the natural tendency is for stick-out to decrease unless the welder consciously maintains the torch distance. Inconsistent stick-out causes fluctuating current and uneven bead appearance.
Frequently Asked Questions
What happens with too much stick-out?
Excessive stick-out preheats the wire more, causing it to melt at a lower current. This reduces penetration into the base metal, increases spatter, and produces a less stable arc. The wire may also wander or curve before reaching the pool, reducing directional accuracy.
Is stick-out the same as arc length?
No. Stick-out is the total distance from the contact tip to the workpiece. Arc length is just the gap between the end of the wire and the surface of the weld pool. Stick-out = electrode extension (wire between contact tip and arc) + arc length. In MIG welding, the electrode extension portion is what produces the resistive preheating effect.