I-CAR AWQT study plan

Map the GMAW circuit from power source through gun, work clamp, and ground path, and explain how voltage, wire feed speed, and inductance each change the arc

Set up a MIG machine on scrap steel: select polarity, install and tension the drive rolls, thread the liner and gun, and set gas flow with a flowmeter

Identify each PPE item required for arc welding and state the specific hazard it controls, including shade number selection for the amperage range used

Demonstrate fume and fire-hazard controls for MIG welding on galvanized and coated steel, including ventilation and coating removal

Diagnose common GMAW defects by adjusting one variable at a time: porosity from gas, spatter from voltage, and lack of fusion from travel speed

Compare short-circuit, globular, and spray transfer and state which thicknesses and positions each suits for automotive sheet steel

Classify steel substrates by test: identify mild steel, high-strength low-alloy, and boron or martensitic grades using OEM body repair information and simple shop checks

Explain heat input and its effect on strength in advanced high-strength steels, and list which grades OEMs restrict from GMAW repair

Tune wire feed speed and voltage on 0.8 mm and 1.2 mm sheet and record the sound and bead appearance at each setting

Trace the STRSW current path through transformer, secondary circuit, electrodes, and overlapping panels, and explain why shunt paths and poor ground change weld quality

Select electrode tip diameter and shape for a given panel stack and state how tip condition changes current density

Set squeeze, weld, hold, and cool times on a squeeze-type resistance spot welder and justify each setting from the stack thickness and coating

List the PPE and burn hazards specific to resistance welding, including fume from coating burnout and hot panel handling

Perform a peel test on a practice coupon and interpret the nugget size and failure mode

Identify aluminum panel alloys used in vehicle bodies and state which are weldable by GMAW and which OEMs direct to rivet bonding or other methods

Set up a push-pull or spool gun feed system for aluminum and correct the typical wire birdnesting and burnback faults

Describe how aluminum oxide film and thermal conductivity change cleaning, preheat, and travel speed compared with steel

Explain dissimilar-metal joining limits and why direct fusion welding of aluminum to steel is generally prohibited in body repair

Compare self-piercing rivets, flow-drill screws, and adhesive bonding as alternatives when fusion welding is not permitted

Set up a MIG brazing process with silicone bronze wire, including correct polarity, gas, and lower heat input than steel welding

Distinguish brazing from welding by joint mechanism and state why silicone bronze suits galvanized and high-strength steel outer panels

Identify the defects unique to brazing: incomplete tinning, burn-through, and zinc burnback at the toe of the bead

Select filler diameter and travel technique for gap filling on a panel joint and control heat to limit distortion

State where OEM procedures prohibit brazing and where they require it in place of GMAW

Perform visual inspection against a written criteria list for porosity, undercut, overlap, spatter, and incomplete fusion on steel and aluminum coupons

Run a destructive test series: bend test, peel test, and chisel test, and record the failure mode each reveals

Measure weld size and penetration where required and compare results with OEM or industry acceptance criteria

Diagnose a root cause for each defect found and state the single process variable to change first

Explain how aluminum weld inspection differs from steel, including oxide entrapment and heat-affected zone softening

Summarize the OEM procedure research steps required before any weld repair: locate the body repair manual section, confirm substrate, and confirm the approved joining method

Explain documentation and liability expectations when a repair deviates from OEM procedure

Review sectioning and partial replacement rules and how they affect weld placement and joint type

Re-test weak areas from earlier weeks by writing and answering 40 mixed practice items across all domains

State corrosion protection requirements after welding and brazing and where seam sealer and cavity wax apply

Complete two full-length timed practice exams and log every miss by domain

Re-study the two lowest-scoring domains using the notes and logs built in weeks 1 through 7

Recite the safety and PPE rules for GMAW, STRSW, and brazing without notes

Explain aloud the correct joining method choice for ten mixed substrate scenarios

Confirm exam-day logistics, approved materials, and time allocation per domain based on weighting