What is wire stickout in MIG welding, and what is a typical recommended distance for solid MIG wire?

• A. Stickout is the distance from the contact tip to the weld pool; about 3/8 inch (9–10 mm)
• B. Stickout is the distance from the contact tip to the weld pool; about 1/4 inch
• C. Stickout is the length of the wire spool
• D. Stickout is the distance from the power source to the workpiece

Answer: (B)

Wire stickout is the distance from the end of the contact tip to the weld pool. For solid MIG wire, a typical recommended stickout is about 1/4 inch (6 mm). This length keeps the arc stable and heat transfer efficient, while reducing spatter and feeding problems. Going longer, around 3/8 inch (9–10 mm), can make the arc unstable and increase the chance of tip overheating or feeding issues. Going too short can cause the tip to contact the molten pool or lead to unstable starts.