GMA Welding for Collision Repair Welding Practice Test

These questions are part of the practice quiz. Start practicing

• Name two common aluminum filler metals and give a typical application for each.
• Which welding technique increases penetration by pointing at the weld bead and dragging away from it?
• Which factor is most associated with reducing spatter when MIG welding on automobiles?
• What is the maximum melt-through width on the backside of a butt joint with backing weld?
• How do you determine the correct filler metal and shielding gas for welding a vehicle frame repair?
• How does the voltage output behave once set on a typical MIG welder?
• For plug welds when no vehicle maker recommendation exists, what hole size should be drilled or punched in the location of the spot welds being replaced?
• What is the effect of increasing wire feed speed on a MIG weld bead if all other settings remain constant?
• During destructive testing of an open butt joint weld, the root of the weld should be on which surface of the bend?
• What are crater cracks in MIG welding, and how can they be prevented in collision repair?
• What is the primary purpose of shielding gas in welding?
• In MIG welding, which setting primarily adjusts current?
• What must be done to the joint before making plug welds?
• Which technique helps reduce heat input when patching a car panel with MIG welding?
• When would you preheat a steel panel in collision repair MIG welding, and what is a typical preheat temperature?
• Which polarity is typically used for GMAW with solid steel wires and shielding gas, and why?
• Which polarity is workpiece positive and electrode negative, used with flux-cored electrode wire?
• GMA (MIG) plug welds join two or more lap pieces together and are used to replace factory spot welds. What type of weld is this?
• Which statement about flux-cored wire is true?
• For collision repairs, which polarity is used most often?
• The backside of a fillet weld should show evidence of penetration in the form of what term?
• Which welding technique involves placing a series of small, spaced welds to spread heat?
• What is the recommended electrode wire for collision repair welding?
• When tuning a welding machine for a vehicle repair, which metal should be used for testing?
• What is a consequence of not using proper tacking during frame patch welding?
• In a butt joint with backing pieces, what should the root gap between the top pieces be relative to the metal thickness?
• Which statement describes short-circuit transfer and spray transfer in GMAW, and which is more common for thin steel body panels?
• During plug weld preparation, holes are drilled or punched in the same locations as the spot welds being replaced. What is the purpose of these holes?
• Increasing stick-out has what effect on amperage output and weld penetration?
• Which shielding gas is commonly used for welding aluminum?
• What effect does root gap size have on a butt joint weld with backing pieces?
• What is the term for the distance from the end of the contact tip to the end of the wire?
• Which sequence best describes a basic door patch repair using GMAW?
• Which of the following lists the three steps of the destructive testing sequence in the correct order?
• Which statement best describes the benefits of DC+ in steel GMAW for spray or short-circuit transfer?
• In some procedures, what type of weld may be used in the backing to connect to the top pieces?
• Plug weld holes should be sized to 8 mm (5/16") when no vehicle maker recommendation exists.
• When preparing a butt joint on a collision repair, what is a typical root gap and why?
• What considerations are required when welding near air-bag components or electronics within a vehicle?
• What is the purpose of backer bars or heat sinks in MIG welding automotive panels, and when would you use them?
• What spool dimension must be at least 300 mm in diameter?
• What bead profile indicates a well-formed MIG weld on a patch panel?
• When plug welding three pieces, how should the hole in the top piece compare to the hole in the middle piece?
• What are the two main wire transfer modes described for GMAW in automotive repair?
• Shielding gas protects the weld from gases that cause what?
• What pre-weld checks should you perform on your welding rig before starting a repair job?
• Which of the following is a MIG weld defect that most directly indicates insufficient fusion?
• Outline a basic sequence for repairing a door skin patch on a vehicle using GMAW.
• During destructive testing of a butt joint with backing weld, what term describes the condition where metal tears away from one base piece while the weld remains with the other piece?
• In the wire designation ER70S-6, what does the number 70 signify?
• Plug weld holes should be sized as the vehicle maker recommends, or, if no recommendation exists, what size should be used?
• What word completes the phrase 'short ______ Welds' in this context?
• How can you prevent porosity caused by moisture in welding wire?
• For plug welds, what must be true about the hole after welding?
• What shielding gas setup is typically used for MIG welding aluminum in collision repair, and what equipment is often required?
• What is the most important surface preparation step before MIG welding on painted or corroded auto body panels?
• What is the purpose of a visually inspected weld bead in collision repair, and what signs indicate acceptance?
• If the drive-roll pressure against the wire is too high, what happens to the wire?
• The melt-through width on the backside should be the same as the width of what on the front side?
• When tuning a welding machine, what should you do with the sample weld?
• What is the stick-out range for 0.6 mm (0.023 in) wire?
• What are typical signs of a good MIG weld in a collision repair context?
• The electrode wire diameter used depends on the ______ required for the welding.
• Which shielding gas nozzle type is typically used with the short-circuit transfer method?
• For a visual inspection, an open butt joint weld must be completely what?
• Causes of poor weld penetration include too low heat setting, travel speed too fast, stick out too long, and improper root gaps.
• MIG welding is noted for requiring what level of post-weld cleaning?
• Which of the following is a valid visual criterion to inspect in a MIG weld on a vehicle panel?
• What is porosity in a MIG weld, and what is a common cause in collision repair work?
• What is a common way to remove copper particle buildup from the welding liner?
• In an open butt joint, the gap between pieces equals how much of the metal thickness?
• What does the contact tip transfer to the electrode wire and must match its diameter?
• Which polarity is electrode positive and workpiece negative and used with solid electrode wire?
• Which welding position is typically described as the overhead position?
• Which weld quality issue is caused by shielding gas not turned on or base metal contamination?
• Name three common defects in MIG welds that are important to inspect in collision repair.
• When MIG welding aluminum, what approach helps manage the oxide layer?
• Which option describes the open butt joint approach in this context regarding burn-through avoidance?
• Which is an advantage of using 75/25 shielding gas for carbon steel MIG welding?
• Before applying additional top coats, what should be done with weld-through primer?
• Travel speed in welding primarily affects which aspect of the weld bead?
• What welding positions are most common for collision repair work on body panels, and which is most challenging?
• Which polarity concentrates most heat on the workpiece?
• In a destructive test of a lap joint, what indicates complete fusion between the metals?
• After completing a MIG weld on a collision repair, what is the recommended cleaning process before finishing?
• What technique helps minimize distortion when patching a car body panel with MIG welding?
• What is the typical shielding gas flow rate in cubic feet per hour (CFH) for Collision Repair welding?
• In an open butt joint, the electrode wire is aimed at the center of what?
• In a butt joint with backing weld, the electrode wire is aimed at which part?
• What is the maximum melt-through height on the backside of an open butt joint weld?
• Duty cycle is how many minutes out of _______ a welding machine can operate continuously at a rated amperage.
• What welding technique is described as using multiple short passes to control heat input?
• Which wire type has limited availability for collision repair welding?
• Which angle controls where the wire is pointed at the joint and affects penetration, shielding gas coverage, and undercut?
• Why is it important to keep shielding gas nozzles clean on a welding torch?
• What is spatter control and how can you reduce it in MIG welding on cars?
• What polarity is typically used when MIG welding carbon steel with ER70S-6 filler?
• What is the recommended path length and technique to ensure a good fillet weld on a door skin patch?
• For general-purpose MIG welding of 0.060 inch carbon steel body panels, which filler metal and polarity are typically used?
• Which AWS code is most commonly referenced for structural welding of steel in collision repair contexts?
• Which welding condition is associated with unbalanced voltage and amperage settings, worn or recessed contact tips, improper shielding gas flow, excessive welding gun angles, and contamination or corrosion of the base metal?
• Why are tack welds important in collision repair before performing a full MIG weld?
• What is the general purpose of the described destructive test for open butt joint welds?
• What is the maximum total of porosity, skips, and voids allowed in open butt joint?
• What is the consequence of not using backer bars or heat sinks on thick sections or joints prone to warping?
• What factor related to welding gun movement directly affects heat input?
• What is the initial step you should take before patch welding a damaged area?
• Which step should you take to prevent a fire when welding near flammable paints, solvents, or aerosols on a vehicle?
• Cracks are allowed in the destructive test only if which condition is met?
• Which plug weld pattern is described as randomly alternating the location of plug welds and not making two or more welds next to each other concurrently?
• Which statement correctly describes GMAW and its difference from FCAW?
• What is the maximum permissible size for a single porosity, skip, or void defect in a butt joint with backing?
• Which three factors help control arc length in GMAW?
• In the described destructive test, under which condition are cracks considered acceptable?
• After the sample is flattened in the destructive test, what is inspected?
• Which welding problem is commonly caused by excessive drive-roll tension, tangled wire, a clogged gun liner, or too small a contact for the wire diameter?
• If welding on a vehicle, which primer should be used to allow welding through the coating?
• Which operation should not reduce the thickness of surrounding material when finishing welds?
• What is a recommended method to prepare aluminum for MIG welding to remove oxide quickly and effectively?
• Why is distortion a critical concern in collision repair MIG welding, and how can it be mitigated?
• How should you store and inspect welding consumables such as wire and tips to ensure quality?
• The heat input in MIG welding is influenced by which factors?
• To pass a visual inspection, a fillet weld must be free of porosity. Which statement best describes porosity allowance?
• Which sequence correctly lists the three steps described for the destructive test?
• What term describes plug welds that are randomly alternating in location and not made two or more welds next to each other concurrently?
• What is the maximum height of a spool of electrode wire?
• What is the second step in the destructive test procedure after aligning the pieces along the weld axes?
• Which term describes the depth of weld fusion into the base metal?
• Which surface contaminants are particularly problematic for MIG welding on painted panels, and how are they removed?
• Which weld defect is associated with heat settings that are too high, travel speed too slow, or root cap width too wide?
• Why is it important to remove coatings such as paint and rust before MIG welding, and what happens if you don't?
• For welding sheet metal, which heat transfer method is preferred due to lower heat?
• In patch repairs, what is the purpose of stitch welds across the patch?
• Which welding position is typically easiest to weld in?
• Melt through that creates a ripple is a sign of ______ weld penetration.
• Which advantage is listed for GMA (MIG) welding?
• Why must the inner diameter of the welding gun liner match the electrode wire diameter?
• Which wire type requires no shielding gas and is not recommended for metal thinner than 18 gauge?
• What is the role of back-step technique in MIG welding to minimize heat buildup in a repair seam?
• Which safety practice is essential when welding near airbag modules to prevent accidental deployment?
• What is an essential PPE item when performing GMAW on vehicle panels to protect eyes from sparks and UV exposure?
• What are the maximum melt-through width and height allowed on the backside of a fillet weld?
• 115 volt welders may require a conversion kit and may also require the ________ to be switched for Collision Repair welding.
• What safety precautions should you take when welding on a vehicle with a full gas cylinder nearby?
• Which coating type should not be removed from surfaces to be welded?
• How many amperes per 0.025 mm (0.001 in) of metal thickness?
• What word completes the phrase 'the ____ of the weld' in the described test?
• Which weld defect may be caused by heat settings that are too high, travel speed too slow, stick out that is too short, incorrect welding gun angles, and root caps that are too wide?
• Which angle name refers to the angle the welding gun is pointed toward or away from the direction of travel?
• The nugget hole diameter for a plug weld made through an 8 mm (5/16") hole must be at least how many millimeters?
• Which bead condition may be caused by an unsteady hand, a worn contact tip, too much stick out, voltage setting too high, and uneven travel speeds?
• Which statement best describes a common approach to minimize distortion when patching a panel?
• What does fit-up refer to in welding practice?
• What is the term for a groove cut into the base metal at one or both sides of the weld bead, which may be caused by unbalanced voltage and amperage settings or improper welding gun angles?
• How should you interpret and apply a welding symbol for a butt weld on a repair patch in the body of a car?
• Why is it important to understand welding symbols when planning a repair on a vehicle?
• When visually inspecting a plug weld, the hole must be completely filled, with a nugget height no more than 3 mm (1/8"), and no cracks, porosity, or undercut.
• What is the purpose of shielding gas in GMAW?
• If the drive-roll pressure against the electrode wire is too low, what is the result?
• Which shielding gas is best for welding aluminum?
• How does the size of the heat-affected zone in MIG welding compare to other processes?
• Which term best describes the method of applying small, separated welds to a joint to control heat input?
• Where should the work clamp be attached in relation to the weld site?
• Skip welds are made by placing short 13-19 mm long weld segments in random locations along the joint and then filling in the spaces. What is this type of weld called?
• Which description best characterizes GMA (MIG) welding?
• What are typical wire diameters used in automotive MIG welding for sheet metal and for thicker sections?
• What is the maximum defect size allowed per porosity, skip, or void in open butt joint?
• What finishing step may be performed after plug welds?
• Which statement correctly describes short-circuit transfer and spray transfer in GMAW, and which is more common for thin steel body panels?
• Which shielding gas produces a much hotter weld bead and is not recommended for high-strength steel?
• Too long an arc length in GMAW increases spatter and reduces arc stability. How can you control it?
• Which defect in a MIG weld indicates potential failure and should be avoided?
• What is a spool gun and when is it recommended in automotive MIG welding?
• Which welding technique decreases penetration by pointing at the weld bead and pushing away from it?
• Describe a proper technique for starting and stopping a MIG weld to minimize crater cracking.
• What is the travel angle for the open butt joint weld described?
• When performing a test plug weld, it should be made on the same type and thickness of metal as that to be welded on the vehicle.
• GMA/MIG fillet welds are what shaped beads?
• A ______ weld is made by starting and stopping briefly between welds.
• What is a typical recommended gap for patch-fitting a body panel to allow for MIG welding and filler, and why?
• GMA MIG plug welds are used to join lap pieces and replace factory spot welds. Which weld is described?
• Which techniques help control heat input and minimize distortion when MIG welding a patch panel?
• ER70S-6 is a type of MIG welding wire characterized as what?
• Travel speed also affects which aspect of the weld bead?
• Flux-Cored Wire is not recommended for metal thinner than which gauge?
• Which option correctly identifies the method used to avoid burn-through in a vehicle open butt joint weld?
• Which tools are commonly used to prepare a patch panel edge for MIG welding on a car body?
• MIG welders are powered input by which type of source and output?
• Which shielding gas mixture is commonly used for MIG welding carbon steel, and what is one advantage?
• When making a fillet weld, the electrode should be aimed at the base metal and the welding gun held at what travel angle?
• During a twist test on a plug weld, what action comes after twisting the top piece off?
• GMA MIG plug welds are made by aiming the electrode at what angle?
• Before setting up a welding machine, what should you read from the equipment maker?
• The ER70 electrode rod has a tensile strength of at least how many psi?
• Porosity in a weld is most often caused by shielding gas issues or contamination such as dirty electrode wire or contaminated base metal. Which of the following is a related factor?
• Why is it important to verify the ground clamp connection before starting a repair weld?
• Causes of poor weld penetration include too low heat settings.
• To avoid burn-through when welding an open butt joint on a vehicle, which technique may be used?
• The backside of a plug weld should show melt through as evidence of penetration, but the melt-through height should be no greater than 1.5 mm (1/16").
• Which action helps minimize crater cracking when finishing a MIG weld?
• Which technique helps maintain a consistent fillet along a patch seam on a door skin?
• Differentiate between lack of fusion and lack of penetration in a MIG weld.
• Which of the following welding techniques is used to limit heat buildup and reduce distortion?
• Which coating should be applied to bare metal before plug welding, if applicable?
• Where can anti-spatter compound be applied on shielding gas nozzles to reduce spatter buildup?
• Where should the work lamp be placed relative to the weld site?
• The butt joint with backing weld uses which work angle?
• Which angle is defined as the angle between the plane of the welding gun and the joint being welded?