Burn back occurs when the welding wire melts back into the contact tip after the arc stops. It is commonly caused by incorrect wire feed speed, excessive voltage, worn or oversized contact tips or poor electrical contact. Correct machine settings, proper stick-out and regular contact-tip replacement prevent it.
This guide covers what causes burn back, how to stop it, the role of the contact tip, and why contact tips burn out.
What causes burn back?
Burn back occurs when the welding wire melts back into the contact tip after the arc stops. It is commonly caused by incorrect wire feed speed, excessive voltage, worn contact tips or poor electrical contact.
Correct machine settings and regular consumable replacement help prevent burn back.
Why does my wire keep burning back?
Repeated burn back usually indicates incorrect wire feed speed, damaged contact tips or excessive stick-out.
Inspect the torch consumables, confirm the wire feed settings and replace worn contact tips where necessary.
How do I stop burn back?
Use the correct wire feed speed, replace worn contact tips, maintain proper stick-out and ensure the wire feeds smoothly through the liner.
Routine torch maintenance is one of the most effective ways to prevent burn back.
Can the contact tip cause burn back?
Yes. A worn or oversized contact tip reduces electrical contact between the wire and the torch, increasing the likelihood of burn back.
Replacing contact tips at regular intervals helps maintain consistent arc performance and reliable wire feeding.
Why is my contact tip burning out?
Contact tips naturally wear over time, but excessive heat, poor electrical contact, incorrect tip size or prolonged high-current welding can shorten their lifespan.
Using the correct contact tip size and replacing worn consumables before failure improves welding performance.
The contact tip is the common thread
Burn back and a short contact-tip life are closely linked — both worsen when the tip is worn, the wrong size or making poor electrical contact. Correct wire feed speed and stick-out matter, but a fresh, correctly sized contact tip is often the single most effective fix. For high-current or high-production work, heavy-duty contact tips offer a longer service life.
Browse contact tips and torch consumables in our welding consumables guide, compare tip options in our process and equipment comparisons, or contact the Weldability SIF technical team.