I-CAR Welding Techniques and Processes

Question 1

Which welding process is most commonly specified by vehicle manufacturers for structural collision repair?

Accepted Answer

Squeeze-type resistance spot welding (STRSW)

Answer

Oxyacetylene welding

Answer

TIG welding

Answer

Flux-core arc welding

Question 2

When performing MIG plug welds as a substitute for factory spot welds, what drill bit size is typically used to prepare the plug weld hole?

Accepted Answer

8 mm (5/16 inch)

Answer

1/4 inch (6 mm)

Answer

3/8 inch (9.5 mm)

Answer

1/2 inch (12 mm)

Question 3

What is the primary reason oxyacetylene welding is generally prohibited on modern high-strength steel (HSS) structural components?

Accepted Answer

The heat-affected zone is too large and degrades HSS properties

Answer

It produces too much slag

Answer

It cannot achieve proper penetration

Answer

Acetylene gas is not hot enough

Question 4

In MIG (GMAW) welding for collision repair, which shielding gas mixture is most widely recommended?

Accepted Answer

75% argon / 25% CO2

Answer

100% argon

Answer

100% CO2

Answer

50% argon / 50% helium

Question 5

What does the term 'heat-affected zone' (HAZ) refer to in welding?

Accepted Answer

The region of base metal that was not melted but had its properties altered by welding heat

Answer

The area where the weld bead is deposited

Answer

The zone where the shielding gas is active

Answer

The discolored area on the surface of the weld bead

Question 6

When welding ultra-high-strength steel (UHSS), why must weld wire selection match the base metal strength?

Accepted Answer

To ensure the weld joint meets or exceeds the base metal's tensile strength

Answer

To prevent the wire from melting too quickly

Answer

To reduce the cost of the repair

Answer

To improve arc starting characteristics

Question 7

Which personal protective equipment (PPE) is specifically required to protect a welder's eyes from UV and IR radiation?

Accepted Answer

A welding helmet with the appropriate shade lens

Answer

Safety glasses with side shields

Answer

A full face shield only

Answer

UV-blocking sunglasses