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Cast (referred to GMAW), is the diameter of a single loop of wire, cut from the spool and laid unrestrained on a flat surface. It is a specification requirement that has to be verified at receiving inspection. Out of tolerance cast can cause wire-feeding problems in the wire feeder and contact tip, which will cause adverse effects on arc stability.


Helix (referred to GMAW), is the vertical distance between the ends of a single loop of wire, cut from the spool and laid unrestrained on a flat surface. It is a specification requirement that has to be verified at receiving inspection. Out of tolerance helix will produce rotation of the wire in the feeder and contact tip, besides wandering of the wire end.