By 
I-CAR is a non-profit training organization for the auto collision industry.
Part of I-CAR’s training programs include automotive welding qualification tests. Since modern automobiles use a single body design, it is important that any weld repair be structurally sound.
I-CAR offers 3 welder qualification tests at authorized test sites in the United States:
- Gas Metal Arc Welding (GMAW) Test for Aluminum
- GMAW test for steel
- structural steel parts
GMAW Aluminum Test Welds Required
3 welds are required…a fillet weld lap joint, a plug weld lap joint, and a backed butt weld joint. These welds are made on two different aluminum alloys and on 2 different aluminum thicknesses.
Aluminum alloys are: 5052-H32 and 6061-T6. Thicknesses are 1mm and 2.5mm (0.040″ and 0.100″)
All 6 welds must pass visual inspection tests and destructive tests.
GMAW test for steel
Weld tests are done with 18 gauge steel. 4 welds are required for this welding certification:
The 4 welds are a fillet weld lap joint, a plug weld lap joint, a butt weld joint with reinforcement, and an open butt weld joint.
Welding certification for structural steel parts
The test weld used for the structural welding certification test is the same type and thickness as that used for the I-CAR Steel GMAW (MIG) welding test. the test is performed using a simulated structural part.
2 joints are required: a backed butt weld joint and an offset fillet weld. Plug welds are also used for a total of 30 welds. To pass the weld test, the welds must pass a visual inspection and the overall length of the part must be within a certain tolerance. It is a distortion test along with a welding certification test.
I-CAR tries to establish some standardization in welding repairs in the automotive industry.
That seems like a good thing.