expectations before assessment - i-car rts...2018-7-23 · welding assessment is intended to...

Aluminum GMA (MIG) Welding WCA03 Assessment

of 8 2018© Inter-Industry Conference on Auto Collision Repair

I-CAR is the world’s leading provider of collision repair assessment required by the auto industry for nearly 40 years. Based on our vast knowledge in delivering our welding certification courses, we have prepared the following to assist participants in being better prepared prior to attending and have a successful learning experience to conduct safe, quality repairs.

Expectations before assessment:

• Participants are expected to be proficient in automotive grade steel welding. • Practice welding aluminum samples or scrap material of similar grade and thickness using

recommended welding equipment. • Be prepared to bring own personal protection equipment consisting of:

o Government issued photo ID o Ear plugs protection o Leather boots or shoes (no athletic/fabric shoes) o Leather welding cape or long sleeve welding shirt o Headwear must be of a non-flammable nature or protected with a suitable welding

hood / cover. (please be aware that some hair products may contain flammable components and should not be used during assessment)

o Welding magnifying lens per individual need for improved vision o Safety glasses (must be worn at all times) o Welding gloves o Welding helmet (auto darkening lens preferred) and corrective lenses if required o New plastic lens cover for welding helmet o Welding respirator (NIOSH approved)

Recommended Shop Equipment

I-CAR recommends the following SHOP EQUIMENT is available in your work area prior to the assessment to be successful when returning to the work area.

• Pulse Synergic MIG Welder, capable of using 1.0mm and 1.2mm electrode wire on weld joints of 1.0mm to 2.5mm thickness

• 100% Argon Shielding gas for Aluminum welding • Extra bottle of 100% Argon shielding gas, for use as back up • 5356 Aluminum welding wire or 5554 Aluminum welding wire • Extra roll of 5356 welding wire or 5554 Aluminum welding wire for use as back up • Fire extinguisher with current inspection tag • Extra consumable supplies: Contact tips (AL), replacement nozzle; Gun liner must match size of

wire used • Drive rolls matched to the type and size of the wire used U-shaped for Aluminum • Recommended: Small parts kit with consumable supplies for each welder listed above



• Recommended: Auxiliary lighting/fluorescent drop light • Sturdy mounted vise mounted in the welding area for destructive testing welds • Welding screens or welding blankets to protect items near welding area

This assessment consists of three major components:

1. Theory

a. This cover the characteristics of welding aluminum, various techniques used, equipment, the technology of “pulse”, and over view of the seven welds within the course

b. The majority of this information is covered in a presentation environment. Were the instructor is engaging discussion and presents lessons.

c. The student will be exposed to the introductions of welding aluminum and why is different than welding steel

2. Hands-On Practice

a. Each student gets to practice the “Certification Welds” with the assistance of the instructor

b. In this portion of the course the student will receive valuable coaching and assessment on the criteria of the “certification welds” and how to produce passing welds.

c. This portion is a prep class to the certification test d. The instructor will provide tips and techniques to get each student to produce successful

and repeatable results

3. Certification Testing

a. The certification test verifies the skills of each student b. Each participant will be required to the produce seven welds shown below that meet

WCA03 visual and destructive testing criteria.



What the participant will experience while in assessment:

The course contains two major components:

• The first component is welding theory; most consider this a certification preparation course. The welding assessment is intended to coach, and guide students to become proficient at welding aluminum with advanced pulse MIG equipment using a structural type electrode wire (5000 series) in various diameters. Students are expected to be proficient in steel welding.

• The second component is certification testing; which is a formal welding test. There are four weld joints, which three of them are performed in vertical and overhead position, but only one weld joint is only performed in vertical. This makes a total of seven tested welds.

Certification Testing

1. The participant will be supplied with 16 Thick (2.5mm) and 20 Thin (1.0mm) welding coupons. This is enough material to perform each weld twice.

2. The participant will be advised they should use scrap material to set-up their welder before welding the test material. And be shown where to find the visual and destructive criteria (Student Handout).

3. the participant will be observed, but NOT provided with any tips or suggestions on the actual welding operation.

4. Once the participant provides the seven welds, they are given one last opportunity to review their certification welds before grading. Once grading begins a pass or fail is determined, there is no going back to re-do any welds.

5. If pass, the participant will be congratulated. A Certificate will be emailed to them at the email address provided at registration. If a participant fails, they will be informed why they failed and what could have been done to correct the problem. They WILL NOT be allowed to retest at this time, and must retake the test at a later date.

6. Participants certification welds will be document the with photographs and sent to I-CAR for audit (see below).

Weld Photographs

If participant passes all seven welds only two pictures are required. Face side and Back side with the I-CAR® welding gauge visible for reference.

Here is an example of a passing participant’s certification welds:

• Passing Certification Welds Face side



• Passing Certification Welds Back side (Tack Welds for demonstration purposes, not required)

If the participant fails the certification test the administering instructor must thoroughly document the failed portions. In the example below this participant failed welds 5 and 7, both failed the destructive test. This will require four pictures one of all seven face side, all seven back side, and one each of the failed portion of welds.



• Failed Certification Test Welds Face side

• Failed Certification Welds Backside

• Failed Certification Weld #5 (Destructive Failure)



• Failed Certification Weld #7 (Destructive Test Failure)

All certifications are built on standards. In the I-CAR® Welding Certification for Aluminum (WCA03) these standards are centered on equipment requirements, visual inspection, and destructive testing. To retain



the credibility of the certification, we must follow all procedures and protocols in addition to documenting the test results.

Thank you,

expectations before assessment - i-car rts...2018-7-23 · welding assessment is intended to...

Documents