Welding Certification – Automotive ICAR Tests

I-CAR is a non-profit training organization for the auto accident industry.

Part of I-CAR’s training programs includes automotive welding qualification tests. With modern uni-body design cars, it is important that any weld repair is structurally sound.

I-CAR offers 3 welder qualification tests at authorized test locations in the United States:

  • Gas Metal Arc Welding (GMAW) test for aluminum
  • GMAW test for steel
  • mild steel parts

GMAW aluminum test welds required

3 welds are required…a fillet welded lap joint, a plug welded lap joint and a butt welded joint with pad. These welds are made on two different aluminum alloys and on two different aluminum thicknesses.

The aluminum alloys are: 5052-H32 and 6061-T6. The thicknesses are 1 mm and 2.5 mm (0.040 inch and 0.100 inch).

All 6 welds must pass visual inspection and destructive testing.

GMAW test for steel

The welding tests are carried out with 18 ga steel. This welding certification requires 4 welds:

The 4 welds are a fillet welded lap joint, a plug welded lap joint, a butt welded joint with pad and an open butt welded joint.

Welding certification for steel components

The weld test used for the structural weld certification test is the same type and thickness used for the I-CAR Steel GMAW (MIG) weld test. the test is carried out on a simulated structural part.

2 joints are required: a backed butt weld and an offset fillet weld. With a total of 30 weld seams, plug welds are also used. To pass the weld inspection, the welds must pass visual inspection and the overall length of the part must be within a specified tolerance. It is a distortion test and a welding certification test.

I-CAR is attempting to establish some standardization of weld repairs in the automotive industry.

That seems like a good thing.