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I-CAR is a non-profit training organization for the auto collision industry.
Part of I-CAR’s training programs includes qualification tests for welding on automobiles. With modern cars using uni-body designs, it is important for any weld repair to be structurally sound.
I-CAR offers 3 welder qualification tests at authorized test sites across the United States:
- Gas Metal Arc Welding (GMAW) Test for Aluminum
- GMAW test for steel
- Structural Steel Parts
GMAW aluminum test weld required
3 welds are required… a fillet welded lap joint, a plug welded lap joint, and a butt welded joint with backing. These welds are made on two different aluminum alloys and 2 different thicknesses of aluminum.
The aluminum alloys are: 5052-H32 and 6061-T6. Thicknesses are 1mm and 2.5mm (.040″ and .100″)
All 6 welds must pass visual inspection test and destructive test.
GMAW test for steel
Welding tests are performed using 18 Ga steel. The 4 welds required for this welding certification are:
The 4 welds are a fillet welded lap joint, a plug welded lap joint, a butt welded joint with backing, and an open butt welded joint.
Welding Certification for Structural Steel Parts
The welding test used for the structural welding certification test is the same type and thickness as used for the I-CAR steel GMAW (MIG) welding test. The test is carried out using a simulated structural part.
It requires 2 joints: a butt welded joint with backing, and an offset fillet weld. Plug welds are also used for a total of 30 welds. To pass a welding test, the weld must pass visual inspection and the total length of the part must be within a certain tolerance. It is a deformation test in addition to being a welding certification test.
I-CAR seeks to establish some standardization in weld repair in the automotive industry.
This sounds like a good thing.
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