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Because less wire stickout typically results in a more stable arc and better low-voltage penetration, the best wire stickout length is generally the shortest one allowable for the appliion. In a MIG welding process, the contact tip is responsible for transferring the welding current to the wire as it passes through the bore, creating the arc.

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To prevent nesting—a tangle of wire that halts the wire from being fed—during FCAW welding, always use knurled V- or U-groove drive rolls in your wire feeder. Compared to a GMAW solid welding wire (which uses a smooth V-groove drive roll), FCAW wire is much softer (due to its tubular design) and if you use the incorrect drive roll, it can easily compress the wire.

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