Abstract: Stickout of a welding electrode wire from a welding torch is determined during welding, and based upon a welding parameter, such as welding current. Different relationships are used for the determination depending upon whether the welding wire is in a short-circuit condition or an arc condition. The stickout may be converted to a standardized unit of measure to make it readily understandable to an operator. The stickout may be logged and associated with other parameters and information, such as workpiece, operator, welding system, date and time. The stickout may be used as the basis for an alarm or a disabling operation. Moreover, the stickout may be provided on a readout for the operator. It may also be used as a basis for controlling a wire feeding apparatus that retracts the welding wire to a desired stickout following a weld.

Abstract: Conduits exiting from a welding torch handle are supported by a stiffening arrangement to limit the angle or radius of curvature of the conduits and thereby to limit strain and possible damage. The stiffening arrangement may include a stiffener that does not extend completely around the conduits, but is captured in a jacket that may be secured to the torch handle and wrapped around the conduits. Alternatively, an integral stiffener or stiffener assembly may include a tongue-like-stiffener extending from the handle to support the conduits and to limit their radius of curvature as they exit the handle.