I-CAR Welding Techniques and Processes 3

Question 1

What is the recommended minimum distance between a weld location and any OEM spot weld when adding supplemental MIG plug welds?

Accepted Answer

25 mm (1 inch)

Answer

5 mm (0.2 inch)

Answer

10 mm (0.4 inch)

Answer

50 mm (2 inches)

Question 2

When sectioning a vehicle's B-pillar, why is staggering weld seams required if multiple layers are present?

Accepted Answer

To prevent all seams from aligning, which would create a single concentrated weak point

Answer

To make the repair easier to inspect visually

Answer

To reduce the total number of welds needed

Answer

To allow for thermal expansion between layers

Question 3

What condition is indicated when a STRSW electrode tip mushrooms or deforms during use?

Accepted Answer

The electrode needs to be dressed or replaced to restore proper tip geometry

Answer

The welder is operating at the correct heat setting

Answer

The metal being welded is too thick

Answer

Shielding gas is not required for resistance spot welding

Question 4

What is the purpose of applying weld-through primer to bare metal flanges before assembling panels for welding?

Accepted Answer

It protects the hidden flange surfaces from corrosion after welding

Answer

It improves electrical conductivity for better weld quality

Answer

It prevents spatter from adhering to the base metal

Answer

It increases the tensile strength of the weld nugget

Question 5

Which of the following is the correct action if porosity is discovered in a structural weld on a completed repair?

Accepted Answer

Grind out the defective weld and re-weld with corrected technique and settings

Answer

Apply filler material to cover the surface voids and refinish

Answer

Leave the weld in place if the porosity is less than 10% of the bead length

Answer

Seal the porosity with epoxy primer and paint

Question 6

When welding near vehicle airbag sensors, fuel lines, or wiring harnesses, what precaution must be taken?

Accepted Answer

Disconnect the battery, remove or shield sensitive components, and follow OEM procedures

Answer

Increase weld voltage to reduce welding time near these components

Answer

Apply electrical tape to wiring before welding nearby

Answer

Disable the welding machine's ground clamp

Question 7

What I-CAR training program specifically provides certification in steel GMA (MIG) welding for collision technicians?

Accepted Answer

Steel GMA Welding (WCS03) qualification test

Answer

Platinum Individual designation

Answer

Pro-Level 1 Structural certification

Answer

Vehicle Technology and Trends (VT001E) course