Long electrical stick-out in FCAW-SS welding primarily increases what?

• A. Increased deposition rates
• B. Increased current
• C. More spatter
• D. Shallower penetration

Answer: (A)

Long stick-out changes how the arc heats the filler wire in FCAW-SS. When the contact tip-to-work distance increases, more of the wire sits in the arc and more of the wire tip is melted and transferred into the weld pool. In flux-cored stainless FCAW, this means more filler metal is deposited in the weld per unit time, raising the deposition rate. Shielding is still provided by the flux, and for a fixed power supply the current often drops as the arc length grows, so increased current isn’t the primary effect. While longer stick-out can affect penetration and spatter, the main outcome described here is the higher rate of metal being deposited.