I-CAR SWQT study plan

Map every GMAW setup variable (wire feed speed, voltage/trim, inductance, stick-out, travel angle, gas flow) to the weld bead defect it causes, and write a one-line cause-and-effect note for each.

Trace a complete shielding gas path from cylinder valve through regulator/flowmeter, hose, solenoid, and gun diffuser, and list the failure point and symptom for each segment.

Classify common filler wires and base-material pairings used in collision repair by strength and intended application, noting where each is and is not acceptable.

Assemble a personal PPE and ventilation checklist covering fume extraction, eye and face protection, fire watch, and cylinder handling, and apply it to three shop scenarios.

Calculate heat input in kJ/in for two sample parameter sets and explain how voltage, amperage, and travel speed each shift the result.

Diagram a complete STRSW circuit from transformer through cables, tongs, electrodes, and workpiece, and label where resistance and voltage drop occur.

Explain the interaction of squeeze force, current, and weld time, and predict the outcome when each is set too low or too high.

Describe electrode tip geometry, material, and dressing requirements, and list the inspection steps to perform before each shift.

Identify the safety hazards unique to resistance welding (pinch points, secondary current paths, shunt paths through adjacent panels, fume) and state the control for each.

Walk through a shunt-path scenario and write the corrective sequence a technician should follow before making a structural spot weld.

Read and interpret weld symbols on a representative body repair drawing: fillet, plug, spot, seam, groove, plus supplementary tail and arrow-side information.

Match joint designs (butt, lap, T, corner, edge) to the weld types and vehicle locations where each is used, and explain why the joint dictates the process.

Describe body construction categories (body-over-frame, unibody, space frame) and identify which structural members carry load in a collision.

Define weld quality acceptance criteria (penetration, bead profile, undercut limits, porosity, spatter, burn-through) and sort a written set of defect descriptions into accept, rework, or reject.

Explain how destructive test methods (peel, chisel, bend, macro etch) reveal different defects and which defects each method can and cannot expose.

Differentiate HSS, AHSS, and UHSS families by metallurgy and strength range, and state the welding process and parameter adjustments each family demands.

Explain why heat input must be minimized on AHSS and UHSS, and describe the metallurgical changes that occur in the heat-affected zone.

Identify where HAZ softening and HAZ cracking occur relative to the weld, and list the OEM-level controls (current limits, pulse, weld time, heat-sink paste, skip welding) used to manage them.

Compare GMAW and STRSW suitability for each steel family and justify a process choice for three specific repair scenarios.

Write the questions a technician must answer before welding any UHSS component, including OEM position statements, sectioning limits, and prohibited operations.

Plan a destructive test program: select coupon material, joint configuration, and test method for GMAW and STRSW samples on AHSS and UHSS.

Perform or simulate peel and chisel tests on spot welds and bend tests on fillet welds, then record nugget size, failure mode, and penetration observations.

Correlate observed defects (incomplete fusion, lack of penetration, porosity, cracking, expulsion) with the parameter or preparation error that caused them.

Diagnose three written case scenarios where a weld failed destructive testing and prescribe the specific setup change required.

Build a visual inspection checklist that a technician can use on the vehicle before any destructive test is permitted.

Locate and interpret OEM repair information for welding and sectioning, identifying where weld locations, processes, and squeeze-type spot weld counts are specified.

Compare OEM requirements across at least three manufacturers and note where they diverge on weld location, filler selection, and structural vs. non-structural repair.

Explain the role of repair procedure research, pre-repair scanning, and documentation in satisfying OEM welding requirements.

Identify prohibited practices (welding on UHSS where not permitted, unapproved sectioning joints, substituting GMAW for STRSW) and state the consequence of each.

Draft the documentation package a shop should retain for a structural weld repair, including procedure reference, parameters used, and test results.

Synthesize safety, joint design, quality, and OEM requirements into a single pre-weld and post-weld workflow for a structural repair.

Answer mixed-domain practice questions under timed conditions and log every miss by domain and root cause (knowledge gap, misread, or unfamiliar term).

Re-teach the five weakest concepts from the log in written form, each with a worked example.

Audit your own weld quality criteria against OEM acceptance language and resolve any conflicts.

Rehearse the documentation sequence for a repair from procedure lookup through final inspection sign-off.

Review every domain using the error log and decision tables built in weeks 1 through 7, closing each open gap with a written correction.

Re-run the full mixed-domain practice set and compare scores and error patterns against week 7.

Recite from memory the parameter relationships, HAZ controls, and OEM documentation steps without reference to notes.

Build a one-page pre-exam reference sheet of formulas, limits, and decision rules you are permitted to bring mentally to the test.

Identify any remaining low-confidence topics and mark them for continued study rather than guessing on exam day.