In GMAW and FCAW, the distance the wire protrudes past the contact tip, called electrode extension, which with arc length makes up contact-tip-to-work distance. Longer stickout preheats the wire by resistance, lowering current and penetration on a constant-voltage machine; shorter stickout runs hotter. Solid wire typically runs about 1/4 to 3/4 inch depending on transfer mode, gas-shielded flux core about 3/4 to 1 inch, and self-shielded wire longer. In GTAW it means how far the tungsten extends past the cup.
You're holding an inch and a half of stickout, that's why the bead's cold and ropey, get in closer.
Flux-cored wires often call for a longer stickout on purpose, so read the wire box instead of copying MIG habits.
Also heard as
- electrode extension
- ESO
Related terms
GMAW
Gas metal arc welding: a continuously fed wire electrode shielded by gas, known in the shop as MIG.
FCAW
Flux-cored arc welding: arc welding with a tubular wire filled with flux, with or without shielding gas.
Cup
The ceramic or glass nozzle on a TIG torch that directs shielding gas; also a MIG gun nozzle.
Penetration
How deep the weld fuses into the base metal or the joint beyond the original surface.