Metal Workrs N1 Exam Memos

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METAL WORKERS THEORY

N1
Typical exam questions
Website: www.ekurhulenitech.co.za Email: [email protected]

T1000(E)(N17)T
NOVEMBER EXAMINATION
NATIONAL CERTIFICATE
METAL WORKERS' THEORY N1

(11022061)
17 November 2016 (X-Paper)

09:00–12:00
Non-programmable calculators may be used.
Candidates need drawing instruments
This question paper consists of 7 pages and 1 addendum.
Copyright reserved Please turn over

(11022061) -2- T1000(E)(N17)T
DEPARTMENT OF HIGHER EDUCATION AND TRAINING

REPUBLIC OF SOUTH AFRICA
TIME: 3 HOURS
MARKS: 100
INSTRUCTIONS AND INFORMATION
1. Answer ALL the questions.
2. Read ALL the questions carefully.
3. QUESTION 3 must be answered on the ADDENDUM and handed in.
4. Number the answers according to the numbering system used in this question
paper.
5. Freehand drawings must be done in pencil and must be neat and reasonably
large.
6. Keep ALL the subsections of questions together.
7. Show ALL the calculation steps where necessary.
8. Write neatly and legibly.

(11022061) -3- T1000(E)(N17)T
QUESTION 1
1.1 Goggles are safety equipment that must be worn to protect the eyes.
List FOUR tasks where goggles must be worn. (4)
1.2 Explain ONE type of accident that can arise when using damaged electric
cables in arc welding. (1)
[5]
QUESTION 2
2.1 Hand chisels have their own cutting action.
2.1.1 List THREE types of hand chisels. (3)
2.1.2 Explain ONE use of each hand chisel listed in QUESTION 2.1.1. (3)
2.2 State ONE use of the following hand tools:
2.2.1 Ball-peen hammer
2.2.2 Sleeve punch
2.2.3 Cross-cut file
2.2.4 Tapered drift

(4 × 1) (4)
[10]

(11022061) -4- T1000(E)(N17)T
QUESTION 3
FIGURE 1 below shows the front view of a right-angled pipe elbow. Answer the
questions that follow on the ADDENDUM (attached). DETACH the ADDENDUM and
hand it in.
75
Ø 50
90
FIGURE 1
3.1 Draw the given view. (2)
3.2 Calculate the circumference of the 50 mm diameter pipe. Use the formula
C = 3,142 × diameter. (2)
3.3 Develop the pipe marked A. (3)
3.4 Develop the pipe marked B. (3)

[10]
QUESTION 4
4.1 Define the following properties of a metal:
4.1.1 Elasticity
4.1.2 Malleability
4.1.3 Brittleness
(3 × 2) (6)
4.2 Differentiate between the toughness and the hardness of a metal. (4)
[10]

(11022061) -5- T1000(E)(N17)T
QUESTION 5
5.1 FIGURE 2 below shows the side view of an angle iron section. Label the parts
marked A–E. Write down only the answer next to the letter (A–E) in the
ANSWER BOOK.
B
A
C
E
D
FIGURE 2 (5)
5.2 What do the following abbreviations stand for?
5.2.1 PCD
5.2.2 CSK
(2 x 1) (2)
[7]
QUESTION 6
6.1 List FOUR safety precautions to be observed when working with a pedestal
drilling machine. (4)
6.2 List THREE safety precautions to be observed when working with horizontal
or vertical bending rolls. (3)
6.3 State ONE function of each of the following machines:
6.3.1 Circular power saw
6.3.2 Radial-arm drilling machine
6.3.3 Bending press

(3 x 1) (3)
[10]

(11022061) -6- T1000(E)(N17)T
QUESTION 7
7.1 Name FOUR types of rivet heads used in an assembly work. (4)
7.2 Explain the following terms that describe the distance between rivets and
between the centre of the rivet and the edge of the metal:
7.2.1 Lap
7.2.2 Landing
7.2.3 Pitch
(3 × 2) (6)
7.3 Name FOUR types of bolts commonly used in an assembly. (4)
7.4 Explain the purpose of the following washers as used in general structural
work:
7.4.1 Flat washer
7.4.2 Spring washer
7.4.3 Taper washer

(3 × 2) (6)
[20]
QUESTION 8
8.1 FIGURE 3 below shows a cutting nozzle in position. Label the parts marked
A–E. Write down only the answer next to the letter (A–E) in the
ANSWER BOOK.
A
B
C D
FIGURE 3 (5)

(11022061) -7- T1000(E)(N17)T
8.2 Explain why gas cylinder valves should be opened slowly. (2)
8.3 Name THREE oxyacetylene welding flame settings. (3)

[10]
QUESTION 9
9.1 Explain the following welding terms:
9.1.1 DC welding machine (1)
9.1.2 Earthing (2)
9.1.3 Reverse polarity (2)
9.2 Explain why the welding electrodes are heavily coated. (2)
9.3 List THREE disadvantages of using an alternating-current welding machine. (3)

[10]
QUESTION 10
The following information is given to make up a steel tank cylinder and to stiffen the
cylinder with an external stiffening ring:
Internal diameter of the cylinder is 770 mm

Thickness of the cylinder is 12 mm
Thickness of the flat bar is 12 mm
Width of the flat bar is 75 mm
Calculate the following:
10.1 The length required to form the internal cylinder.
10.2 The length required to form the external stiffening ring from the flat bar.
(2 × 4) [8]
TOTAL: 100
Copyright reserved
(11022061) T1000(E)(N17)T
ADDENDUM EXAMINATION NUMBER:
QUESTION 3
Copyright reserved
MARKING GUIDELINE
17 NOVEMBER 2016
This marking guideline consists of 7 pages.

MARKING GUIDELINE -2- T1000(E)(N17)T
QUESTION 1
1.1  When emery wheels are used.

 When a chipping hammer is used.
 When materials are welded.
 When hitting brittle material such as welding slag or removing rust from
plates. (Any relevant 4 × 1) (4)
1.2 Electric shock will occur. (1)

[5]
QUESTION 2
2.1 2.1.1  Flat/chipping chisel

 Cross-cut/grooving chisel
 Diamond-point/hollowing chisel (3)
2.1.1  Flat chisel – used for removing waste or excess metal or cutting
rods, bars or thin plate.
 Cross-cut chisel – used to cut or enlarge keyways in shafts or
pulleys.
 Diamond-point chisel – used for opening or gouging a cracked
machine casing. (3)
2.2 2.2.1 It is used for light riveting work.
2.2.2 It is used when a large number of items are to be marked from a

template made from wood.
2.2.3 It is used to cut or enlarge keyways in shafts or pulleys.
2.2.4 It is used to align the holes in flanges of pipes when pipe columns
are assembled.
(4 × 1) (4)
[10]

QUESTION 3
3.1
(2)

3.2 C = 3,142 x 50 = 157,1 (2)
3.3 See drawing. (3)
3.4 See drawing. (3)

[10]
QUESTION 4
4.1 4.1.1 Elasticity refers to the ability of a metal to return to its original
shape after being stretched, bent, compressed or deformed.
4.1.2 A malleable metal can be hammered into a shape without

cracking.
4.1.3 Brittleness refers to the impactstrength of the metal.

A brittle metal has a low resistance to impact and will break or snap
before it will bend.
(3 × 2) (6)
4.2 TOUGHNESS
 It is the material's ability to withstand impact or hammering loads without
cracking or breaking.
HARDNESS
 It is the material's ability to resist wear, scratching or damage to its
surface. (2 × 2) (4)
[10]
QUESTION 5
5.1 A – Toe
B – Heel
C – Root thickness
D – Flange
E – Root (5 × 1) (5)
5.2 5.2.1 Pitch circle diameter
5.2.2 Countersunk
(2 × 1) (2)
[7]

QUESTION 6
6.1  Ensure that the job to be drilled is firmly clamped before starting the drilling
machine.
 Make sure that the RPM of the drilling machine is correct before you start
to drill.
 Do not try to hold the job to be drilled with your hand.
 Use a wooden stick to remove the drill shavings from the drill bits. (4 × 1) (4)
6.2  Make sure that the rollers are clean and free from grease or oil.
 Check that the plate or bar you are going to roll is securely held or
supported.
 Ensure that the area around the rolling machine is clear. (3 × 1) (3)
6.3 6.3.1 It is used to cut steel profiles such as I-beams and angle irons.
6.3.2 It is used for drilling steel sections.
6.3.3 It is used to bend steel plates or flat bar sections at various angles.
(3 × 1) (3)
[10]
QUESTION 7
7.1  Snap head

 Pan head
 Countersunk rivet
 Conical head (4 × 1) (4)
7.2 7.2.1 The lap is the contact length between the two plates joined by the
rivets.
7.2.2 The landing is the distance from the centre of the rivet to the
edge of the plate.
7.2.3 The pitch is the distance between the centres of the rivets in a
straight line.
(3 × 2) (6)
7.3  Black bolt

 Machined bolt
 High-carbon steel bolt
 Countersunk bolt
 Huck or tack bolt (Any 4 × 1) (4)

7.4 7.4.1 Flat washers are used under the nut to prevent damage to the
surface of the metal and to ensure that the nut has sufficient
thread to be tightened properly.
7.4.2 A spring washer is placed under the nut to exert additional tension
between the threads of the nut and the bolt to prevent the bolt
from opening during vibration.
7.4.3 The tapered washer is used to ensure that the contact surfaces
of the bolt head and the nut are square to the hole.
(3 × 2) (6)
[20]
QUESTION 8
8.1 A – Mixture of fuel gas and oxygen

B – Pre-heating flame
C – Stream of pure oxygen
D – Drag lines
E – Slag (5)
8.2  To avoid cylinder valves from getting damaged and a possible explosion.
 The pressure gauge of the valve can be damaged. (2 × 1) (2)
8.3  Neutral flame

 Carburising flame
 Oxidising flame (3 × 1) (3)
[10]
QUESTION 9
9.1 9.1.1 It generates direct current for welding purposes. (1)
9.1.2 It ensures the complete welding cycle and prevents electric

shock. (2)
9.1.3 The electrode holder is connected to the positive pole of the DC

welding machine whereas the metal being welded is connected
to the negative pole. (2)
9.2  Electrodes are heavily coated to substantially improve the strength and
ductility of the deposited welded metal.
 It gives off a gas that shields the arc from oxygen and nitrogen in the air.
 It gives off gases and forms slag that protects the weld. (Any 2 × 1) (2)

9.3  The electrode must have a medium to heavy coating.

 Higher open-circuit voltages must be used.
 The polarity of the transformer cannot be set to control the heat distribution
between the tip of the electrode and the metal being welded. (3 × 1) (3)
[10]
QUESTION 10
10.1 Length of cylinder = π × MD

Mean diameter = 770 mm + (6 mm + 6 mm)
= 782 mm
Length of cylinder = π × mean diameter
= π × 782
= 2456,73 mm  (4)
10.2 External stiffening ring:

Outside diameter of cylinder = 770 + 12 + 12
= 794 mm
Length of stiffening ring = π × MD
Mean diameter of stiffening ring = 794 + (6 + 6)
= 806 mm
Length of stiffening ring = π × 806 mm
= 2532,12 mm (4)
[8]
TOTAL 100
Copyright reserved
T1080(E)(M30)T
APRIL EXAMINATION

(11022061)
30 March 2016 (X-Paper)

9:00–12:00
REQUIREMENTS: Drawing instruments
Calculators may be used.

(11022061) -2- T1080(E)(M30)T

METAL WORKER'S THEORY N1
TIME: 3 HOURS
MARKS: 100
paper.
5. Show ALL the steps where calculations should be done.
6. QUESTION 3 should be answered on the ADDENDUM and handed in.
7. Use π = 3,142

(11022061) -3- T1080(E)(M30)T
QUESTION 1
1.1 Define an accident. (2)
1.2 State the legislation act that caters for safety in the workplace. (3)
[5]
QUESTION 2
2.1 State the hand tool that will be used for the following:
2.1.1 Cutting square or rectangular grooves into metal
2.1.2 For lining up the holes for bolting or riveting work
2.1.3 To grip pipes or badly worn nuts
2.1.4 For removing waste or excess metal and cutting rods, bars or
plates
2.1.5 For filing softer metals such as brass and copper

(5 × 1) (5)
2.2 Describe the angle of presentation with reference to chisels. (2)
2.3 Describe the function of each of the following marking-off tools:
2.3.1 Scriber
2.3.2 Inside callipers
2.3.3 Trammels
2.3.4 Chalk line
2.3.5 Steel folding rule

(5 × 1) (5)
2.4 A right-angled gusset steel plate is to be manufactured using the following

measurements:
The vertical side = 250 mm

The horizontal side = 164 mm
Calculate the length of its hypotenuse side.
HINT: R2 = H2 + V2 (3)
[15]

(11022061) -4- T1080(E)(M30)T
QUESTION 3
Use FIGURE 1 on the ADDENDUM (attached) to answer this question. Drawing

instruments should be used.
FIGURE 1 shows a T-piece between two unequal diameter steel pipes.
3.1 Draw the line of penetration between the two pipes. (2)
3.2 Calculate the circumference of the 33 mm diameter pipe. (2)
3.3 Develop the shape of the hole in the main pipe. (2)
3.4 Develop the pattern of the branch pipe.
HINT: C = 3,142 x D
Hand in the ADDENDUM on completion inside your ANSWER BOOK. (4)
[10]
QUESTION 4
4.1 State the meaning of the following abbreviations:
4.1.1 UB
4.1.2 O/D
4.1.3 SOP
(3 × 1) (3)
4.2 Define the following metal properties:
4.2.1 Hardness
4.2.2 Toughness
4.2.3 Elasticity
(3 × 1) (3)
4.3 Describe the nature of the mild steel with reference to the following:
4.3.1 Colour (1)
4.3.2 Carbon content (1)
4.3.3 Uses (2)
4.4 Calculate the back mark of a 220 mm x 80 mm rolled steel channel in

reference to its flange. (2)
[12]

(11022061) -5- T1080(E)(M30)T
QUESTION 5
5.1 Name FIVE safety precautions that should be considered before and during
the use of each machine stated below:
5.1.1 Guillotine
5.1.2 Pedestal grinding machine

(2 × 5) [10]
QUESTION 6
6.1 Draw the front and top views of a double riveted lap joint with the snap head
rivet in position. (3)
6.2 Define the following terms as applicable to assembly work:
6.2.1 Pitch
6.2.2 Landing
(2 × 1) (2)
6.3 Calculate the length of a black bolt that will be used for assembling THREE
12 mm thick steel plates. The maximum diameter of the hole to be drilled
is 18 mm. (3)
6.4 Explain the use of the countersunk bolt during assembly work. (2)
[10]
QUESTION 7
7.1 State the function of each of the following gas apparatus:
7.1.1 Welding torch
7.1.2 Welding hose
7.1.3 Oxygen pressure gauge
7.1.4 Acetylene flash back arrestor
7.1.5 LP-gas cylinder

(5 × 1) (5)

7.2 Describe the following oxyacetylene gas flame settings and their function:
7.2.1 Neutral
7.2.2 Oxidising
(2 × 2) (4)
7.3 State FOUR causes of backfire during gas cutting. (4)
7.4 Explain how to extinguish the flame in the oxyacetylene welding process. (2)
[15]
QUESTION 8
8.1 Define the shielded arc welding process. (2)
8.2 Name SIX protective clothing that should be worn during arc welding and give
reasons. (6)
8.3 Indicate whether the following statements are TRUE or FALSE. Choose the
answer and write only 'true' or 'false' next to the question number
(8.3.1–8.3.3) in the ANSWER BOOK.
8.3.1 Slag protects the weld from atmospheric pollution.
8.3.2 A low current results in a good welding joint.
8.3.3 Porosity is the result of an incorrect welding rod.

(3 × 1) (3)
8.4 State FOUR disadvantages in using a direct-current welding machine. (4)

[15]
QUESTION 9
The internal diameter of a cylinder is 670 mm made out of a 6 mm thick steel plate.
The cylinder is secured with a 10 mm thick stiffening ring.
9.1 Calculate the length of the material required to form the cylinder.
9.2 Calculate the length of a round bar required to form a stiffening ring.
(2 × 4) [8]
TOTAL: 100
Copyright reserved
(11022061) T1080(E)(M30)T
ADDENDUM EXAMINATION NUMBER:
FIGURE 1
Copyright reserved
MARKING GUIDELINE
APRIL EXAMINATION
30 MARCH 2016

MARKING GUIDELINE -2- T1080(E)(M30)T
QUESTION 1
1.1 It is an unplanned and uncontrolled incident which is caused by unsafe acts or

unsafe conditions that result in, or has the potential for physical harm to
persons or damage to property. (2)
1.2 Occupational Health and Safety Act (3)

[5]
QUESTION 2
2.1 2.1.1 Cross cut chisel
2.1.2 Barrel drift
2.1.3 Wrench
2.1.4 Flat or cold chisel
2.1.5 Single cut file

(5 × 1) (5)
2.2 It is the angle at which the chisel is held in relation to the workpiece. (2)
2.3 2.3.1 It is used to scribe a permanent mark or groove onto mild steel
plates or sections.
2.3.2 It is used for measuring internal sizes for example the inside of
diameters of holes or pipes.
2.3.3 It is used to scribe circles with a radius greater than 400 mm.
2.3.4 It is used to strike long straight lines on steel plates or on template

loft floor.
2.3.5 It is used to measure or mark off angles or bevels.

(5 × 1) (5)
2.4 R2 = H2 + V2
= (250 mm)2 + (164 mm)2 (1)
= 62 500 mm2 + 26 896 mm2 (0,5)
= √89 396 mm2
(0,5)
= 298,99 mm (3)
[15]

QUESTION 3
3.1 See the sketch (2)
3.2 C = 3,142 x 33 mm
= 103,69 mm (2)
3.3 See the diagram (2)

[10]
QUESTION 4
4.1 4.1.1 Universal beam

4.1.2 Outside diameter
4.1.3 Setting out point
(3 × 1) (3)
4.2 4.2.1 It is the metal’s ability to resist wear, scratching or damage on the
surface of the metal or the ability to cut other metals.
4.2.2 Toughness is a quality of strength and resistance against breaking

when being bent or twisted.
4.2.3 It is the ability of the metal to return to its original size or form.
(3 × 1) (3)
4.3 4.3.1 Grey (1)
4.3.2 Carbon content is between 0,1% and 0,3% (1)
4.3.3 Used to manufacture steel profiles such as angle iron, channels,

round bars, steel plates, rivets, bolts and nuts (2)
4.4 Back mark = (80 mm + 12 mm) (0,5)

= 92 mm ÷ 2 (0,5)
= 46 mm (2)
[12]

QUESTION 5
5.1 5.1.1  Adjust the machine to the correct size of the plate to be
sheared.
 Under no circumstances may a machine be overloaded.
 Ensure that the machine blades are in good working condition
 Wipe off any grease or oil on the plate to be cut
 Remove any obstructive object behind the machine.
 One person at a time to operate the machine
 Avoid fingers from getting trapped beneath the plate to be cut.
5.1.2  Wear goggles

 Check the grinding wheel for cracks
 Ensure that the machine guards are in position
 Ensure that the work rest is set at a suitable distance
 Adjust the machine to the correct working speed
 One person at a time should operate the machine
 Avoid horseplay when working on the machine
 Avoid loose hanging clothing when working on the machine
(2 × 5) [10]
QUESTION 6
6.1
(3)
6.2 6.2.1 It is the distance measured between two centre points of the holes
along the straight line.
6.2.2 It is the distance measured from the edge of the metal to the centre
of the hole.
(2 × 1) (2)
6.3 Length = thickness of material + 1,5 x diameter of bolt + 3 mm for every

12 mm of material used
= 3 x 12 mm + (1,5 x 18 mm) + 3 x 3 mm
= (36 + 27 + 9) mm
= 72 mm (3)
6.4 It is used where the bolt head should be set flush or in line with the surface of
the plate and where excessive vibration is experienced such as in boilers. (2)
[10]
QUESTION 7
7.1 7.1.1 It is used to store the LP-gas.
7.1.2 It transports the gas from the cylinder to the welding/cutting torch.
7.1.3 It regulates the flow of the oxygen gas leaving the cylinder to the
welding hose.
7.1.4 It is used to prevent the burning gas entering back into the cylinder.
7.1.5 It is used for cutting metal.

(5 × 1) (5)
7.2 7.2.1 A neutral flame has equal amounts of oxygen gas and acetylene
gas. It is used for welding steel such as mild steel and stainless
steel.
7.2.2 An oxidising flame has an excess amount of oxygen. It is used for

brazing and bronze welding.
(2 × 2) (4)
7.3  Dirty nozzle

 Unequal amounts of gasses
 An overheated nozzle
 The welding nozzle is held too close to the workpiece
 Incorrect cutting speed (Any 4 × 1) (4)
7.4 Close the acetylene gas first then the oxygen gas. (2)
[15]

QUESTION 8
8.1 It refers to all types of electric arc welding where the molten metal is shielded
from the atmosphere by a neutral gas. (2)
8.2  A leather apron protects the body against ultraviolet rays and arc rays.
 Overalls are used for body protection.
 Safety boots protect the feet against heavy falling objects
 Leather spats are worn for feet protection.
 Leather gloves are used for hand protection.
 Leather yoke protects the back and shoulders from sparks and hot globular
metals. (6)
8.3 8.3.1 True

8.3.2 False
8.3.3 True
(3 × 1) (3)
8.4  The generator is complex and has many moving parts which will cause
wear.
 Maintenance costs are much higher on a generator than on a transformer.
 A generator is considerably more expensive than a transformer producing
comparable welding current.
Above 200 amperes the magnetic effect of the electric arc created by the
direct current causes an arc-blow.
(4)
[15]
QUESTION 9
9.1 Cylinder:
Mean diameter = 670 mm – 6 mm

= 664 mm
Circumference = 3,142 × 664 mm
= 2 086,29 mm
9.2 Stiffening ring:

Mean diameter = 670 mm + 12 mm + 10 mm (1)
= 692 mm (1)
Circumference = 3,142 × 692 mm (1)
= 2 174,26 mm (1)
(2 × 4) [8]
TOTAL: 100

ADDENDUM
3.4
(4)
FIGURE 1
Copyright reserved
(110122061) -1- T1080(E)(A3)T
T1080(E)(A3)T
AUGUST EXAMINATION

(11022061)
3 August 2015 (Y-Paper)

13:00–16:00
Candidates need drawing instruments.

(11022061) -2- T1080(E)(A3)T

TIME: 3 HOURS
MARKS: 100
3. QUESTION 3 must be answered on the attached ADDENDUM and handed in

with the ANSWER BOOK.
paper.
6. Show ALL the calculation steps where necessary.

(11022061) -3- T1080(E)(A3)T
QUESTION 1
1.1 Name ONE legislation act that governs the working conditions, rights and
responsibilities of a person employed as a metal worker. (1)
1.2 State THREE safety precautions that should be observed to prevent

accidents caused by electricity. (3)
1.3 Define the term standardised colour coding system. (1)

[5]
QUESTION 2
2.1 Choose a description from COLUMN B that matches a/an word/item in

COLUMN A. Write only the letters (A–F) next to the question number
COLUMN A COLUMN B
2.1.1 Ballpeen hammer A chips the slag from the welding
2.1.2 Sledge hammer B when flat or round bars must be bent

to form a circle
2.1.3 Chipping hammer
C striking a centre punch and for
2.1.4 Straight-peen hammer general hammering in the workshop
2.1.5 Cross-peen hammer D very heavy work or support light

riveting
E when flat or round bars must be bent

to form a radius
F to wedge a work piece

(5 × 1) (5)
2.2 Many problems are encountered when a hacksaw is used incorrectly.
2.2.1 Name THREE problems that are encountered when using the
hacksaw incorrectly. (3)
2.2.2 State ONE cause that contributed to the problem listed in

QUESTION 2.2.1 when using the hacksaw incorrectly. (3)
2.3 Illustrate, with the aid of a neat sketch, a sleeve punch and label the parts. (4)
[15]

(11022061) -4- T1080(E)(A3)T
QUESTION 3
3.1 FIGURE 1 below shows two views of a T-Piece with equal diameters of 40
mm.
Draw the T-Piece on the attached ADDENDUM. Detach the ADDENDUM and
hand it in with the ANSWER BOOK.
Hint: Circumference = π × D
30
60
FIGURE 1
3.1.1 Draw the given views. (2)
3.1.2 Determine the line of penetration. (2)
3.1.3 Construct the shape of the hole on the main pipe 'A'. (3)
3.1.4 Develop the pattern of the plate that is required to make up the
branch pipe 'B'. (3)
[10]
QUESTION 4
4.1 Explain the properties of the following metals:
4.1.1 Hardness (2)
4.1.2 Stainless steel (2)
4.1.3 Copper (3)

(11022061) -5- T1080(E)(A3)T
4.2 The table below shows a number of abbreviations that are used when
marking-off plates and profiles in a workshop.
Draw the table in the ANSWER BOOK and write down the answer next to the
question number (4.2.1–4.2.5) in the ANSWER BOOK.
NOTE: The first abbreviation is an example.
Abbreviations Complete name of abbreviations

Example: CL CENTRE LINE
4.2.1 ... this side up

DRG 4.2.2 ...
4.2.3 ... roller steel joist
CSK 4.2.4 ...
4.2.5 ... galvanised
(5 × 1) (5)
[12]
QUESTION 5
5.1 State TWO safety precautions when working with a pedestal drilling machine. (2)
5.2 FIGURE 2 below show a pedestal grinder.
Write down the letters (A–E) and next to the letters the name of each part of
the pedestal grinder in the ANSWER BOOK.
A
B
FIGURE 2 (5)
5.3 Discuss the use of the punching machine. (3)
[10]
(11022061) -6- T1080(E)(A3)T
QUESTION 6
6.1 There are three different types of washers used during structural assembly.
6.1.1 Name the THREE types of washers that are used. (3)
6.1.2 State ONE use of each washer that is listed in QUESTION 5.1.1. (3)
6.2 Explain how rivets are used to join steel sections or plates permanently. (4)
[10]
QUESTION 7
7.1 The table below indicates the different types of cylinders that are used in
cutting or welding.
Write down the numbers (7.1.1–7.1.5) and next to the numbers the correct
answer in the ANSWER BOOK.
CYLINDERS COLOUR THREAD TYPE

7.1.1 … Black 7.1.2 …
Acetylene 7.1.3 … Left hand thread
7.1.4 … Silver 7.1.5 …
(5 × 1) (5)
7.2 Explain how you would test the oxy-acetylene equipment for any gas leaks. (5)
7.3 Illustrate, with the aid of the sketch, the rightward welding technique showing
the direction of weld, angle of the filler rod and the angle of the gas-welding
torch. (3)
7.4 Name TWO types of safety clothing to be worn when working with the oxy-
acetylene equipment. (2)
[15]

(11022061) -7- T1080(E)(A3)T
QUESTION 8
8.1 FIGURE 3 below shows SMAW welding process. Write the letters (A–H) and
next to the letters the labels in the ANSWER BOOK.
FIGURE 3 (8 × 1) (8)
8.2 State ONE difference between direct current and alternating current. (2)
8.3 State FIVE safety precautions that must be carried out before any welding is
done. (5)
[15]
QUESTION 9
9.1 FIGURE 4 below shows a view of a 6 mm thick flat bar bracket that is
required to clamp a channel against the wall.
110 mm
62 mm
50 mm 70 mm
FIGURE 4
9.1.1 Calculate the length of the flat bar to make up ONE clamp. (6)
9.1.2 Calculate the total length of the flat bar to make up FOUR clamps. (2)
[8]
TOTAL: 100
(11022061) -8- T1080(E)(A3)T
EXAMINATION NUMBER:
ADDENDUM
CENTRE NUMBER:
Copyright reserved
MARKING GUIDELINE
AUGUST EXAMINATION
METALWORKERS' THEORY N1
3 AUGUST 2015

MARKING GUIDELINE -2- T1080(E)(A3)T
QUESTION 1
1.1  The Workman's Compensation Act

 The Occupational Health and Safety Act
 The Minerals Act (Any 1 × 1) (1)
1.2  Check that the three-pin plug is correctly wired.

 Ensure that the machine has a proper earth connection.
 Do not use wet hands when working with electricity.
 Ensure that nobody is working on the power line before switching it on.
 Transformers for lead lights must always be used to reduce voltage in
confined spaces during repairs.
(Any 3 × 1) (3)
1.3 Standardised colour coding system is used to identify pipelines, machines,

electrical switch gear, emergency stop buttons, doorways and walkways. (1)
[5]
QUESTION 2
2.1 2.1.1 C
2.1.2 D
2.1.3 A
2.1.4 B
2.1.5 E (5 × 1) (5)
2.2 2.2.1  Broken blades

 Broken teeth
 Excessive wear
 Crooked cuts (3 × 1) (3)
2.2.2 Broken blades

 Too much downward pressure on the cutting blade
 Hacksaw not held firmly
 Cutting strokes not even
 The job is not firmly clamped
Broken teeth
 The job is not firmly clamped in the bench vice
 The blade is not suitable for the metal been cut
 The cutting strokes are too fast
 Downward pressure is not even
Excessive wear
 The metal been cut is too hard
 The job is not firmly clamped in the bench vice
 Insufficient tension on the hacksaw
 The teeth of the blade face the wrong way

Crocked cuts
 Too much downward pressure on the cutting blade
 Hacksaw not held firmly
 Cutting strokes not even
 The job is not firmly clamped
 Insufficient tension on the hacksaw blade
(Any 3 × 1) (3)
2.3

punch
sleeve
(2 marks for drawing and 2 marks for label)
(4)
[15]

QUESTION 3
[10]

QUESTION 4
4.1 4.1.1 Hardness of material has the ability to resist wear, scratching or
damage to the surface of the material. (2)
4.1.2 Stainless steel is corrosive resistant, heat resistant and abrasive

resistant. (2)
4.1.3 Copper has a high malleability, cannot be tempered and also a

good conductor of electricity. (3)
4.2 ABBREVIATIONS COMPLETE NAME OF

ABBREVIATIONS
Example: CL CENTRE LINE
4.2.1 TSU THIS SIDE UP

DRG 4.2.2 DRAWING
4.2.3. RSJ ROLLED STEEL JOIST
CSK 4.2.4. COUNTERSUNK
4.2.5. GALV GALVANISED
(5 × 1) (5)
[12]
QUESTION 5
5.1  Ensure that the work piece is secured before drilling can commence.
 Make sure that the correct RPM is set before drilling.
 Do not hold work piece with the hand when drilling is going to take place.
 Beware of the shavings of metal that is been removed while drilling.
(Any 2 × 1) (2)
5.2  Grinding wheel guard

 Grinding wheel
 Work-piece rest or tool rest
 On – off switch
 Stand (5 × 1) (5)
5.3 The punching machine provides a quick, cheap method of punching holes in
mild plates and sections. When the punch leaves the burr at the bottom of
the plate then the holes are not possible to be used for machined bolts.
Ensure that the correct die is fitting with the correct punch. (3)
[10]

QUESTION 6
6.1 6.1.1  Flat washer

 Spring washer
 Tapered washer (3)
6.1.2 Flat washer

 Used under nuts to prevent damage to the surface of the metal
and also ensure that the nut has sufficient thread to be tightened
properly
Spring washer
 Used for exerting extra tension between the treads of the nuts
and the bolts
Tapered washer
 This is used on tapered flanges on profiles to ensure that the
contact surface of the bolt head and the nut are square to the
hole (Any 3 × 1) (3)
6.2 Rivets are normally used when permanent joints must be made. For light
work cold rivets are used and heavy structural work hot riveting is used. The
rivet is heated by the furnace until it is red hot and then inserted into the holes
and the river head is formed by hammering the head or a hydraulic riveting
machine is used. As it cools down the metal contracts and applies great
pressure to the joint.  (4)
[10]
QUESTION 7
7.1 7.1.1 Oxygen

7.1.2 Right hand thread
7.1.3 Maroon
7.1.4 Low Petroleum Gas (LPG)
7.1.5 Left hand thread (5 × 1) (5)
7.2 To test for gas leaks you must use a soapy solution mixture. Mix the soap
solution properly and apply to all the joints of the oxy-acetylene equipment by
using a paint brush. If there is a leak the soap solution will start to bubble.
Do not continue using the equipment until the leak is repaired. Do not use
matches, bodied plastic lighters or the nose to smell for gas leaks. (5)

7.3
Direction of weld
30°- 40° 40° - 50°
(3)
7.4  Safety gloves

 Leather apron
 Leather spats
 Safety boots
 Heat resistance overalls (Any 2 × 1) (2)
[15]
QUESTION 8
8.1  Electrode
 Flux covering
 Electrode metal
 Gas shield
 Slag coating
 Weld bead
 Molten pool
 Molten metal (8 × 1) (8)
8.2 Direct current is generated by a generator driven by an internal combustion

motor or an electric motor.
Alternating current has no polarity as the positi.

(2)
8.3  Check all electrical connections and earth connections.

 Check the welding cables are in good condition.
 Check the electrode holder and that clamp are in good condition.
 Ensure that welding screens are placed to protect other workers.
 Ensure cables are kept clear away from walkways during welding.
 Ensure that there is adequate ventilation when welding. (Any 5 × 1) (5)
[15]

QUESTION 9
9.1 9.1.1 A = 50 – 6
= 44 mm
B = (62 – 12) x 2
= 50 mm x 2
= 100 mm
C = 110 – 12
= 98 mm
D = 70 – 6
= 64 mm
Total length of one clamp = A + B + C + D

= 44 mm + 100 mm + 98 mm + 64 mm
= 306 mm (6)
9.1.2 Total length of FOUR clamps = 306 x 4 mm

= 1 224 mm (2)
[8]
TOTAL: 100
Copyright reserved
T1080(E)(A16)T
APRIL EXAMINATION

(11022061)
16 April 2015 (Y-Paper)

13:00–16:00
REQUIREMENTS: Drawing instruments
This question paper consists of 7 pages and 2 diagram sheets.

(11022061) -2- T1080(E)(A16)T

METAL WORKER'S THEORY N1
TIME: 3 HOURS
MARKS: 100
paper.
5. Show ALL the calculation steps where calculations should be done.
6. QUESTION 3 must be answered on SUPPLEMENT A and then be handed in.
7. Use π = 3,142.

(11022061) -3- T1080(E)(A16)T
QUESTION 1
Describe if the following is regarded as 'Unsafe conditions' or 'Unsafe acts'.
1.1 Machine unguarded.
1.2 No personal protective equipment.
1.3 Unsafe speed of working.
1.4 Working without authority.
1.5 Overcrowding.
(5 × 1) [5]
QUESTION 2
2.1 Describe the function of each of the following hand tools:
2.1.1 Centre punch
2.1.2 Flat file
2.1.3 Sledge hammer
2.1.4 Hacksaw
2.1.5 Barrel drift

(5 × 1) (5)
2.2 State the correct marking-off tool that should be used in the following:
2.2.1 Measuring the outside diameter of the shaft.
2.2.2 Marking the centres of the holes before it is punched.
2.2.3 Marking-off from the templates.
2.2.4 Marking-off bevels on steel sections.
2.2.5 To check the accuracy of small jobs for marking off angles,
channels and flat bars.
(5 × 1) (5)
2.3 Make neat sketches of the following steel profiles:
2.3.1 Unequal leg angle iron
2.3.2 Universal beam

(2 × 1) (2)

(11022061) -4- T1080(E)(A16)T
2.4 Calculate the hypotenuse of a right-angled triangle with the following

measurements:
The vertical side = 245 mm

The horisontal side = 328 mm
HINT: R2 = H2 + V2 (3)
[15]
QUESTION 3
Use FIGURE 1, DIAGRAM SHEET 1 (attached) to answer this question. Drawing

instruments must be used.
FIGURE 1 shows a T- piece between two unequal diameter steel pipes.
3.1 Draw the line of penetration between the two pipes. (2)
3.4 Develop the pattern of the branch pipe. (4)
HINT: C = 3,142 × D
Hand in DIAGRAM SHEET 1 on completion.

[10]
QUESTION 4
4.1 Name TWO uses of each of the following metals:
4.1.1 Stainless steel
4.1.2 Aluminium
(2 × 2) (4)
4.2 Define the following:
4.2.1 Ductility
4.2.2 Malleability
4.2.3 Fusibility
(3 × 1) (3)

(11022061) -5- T1080(E)(A16)T
4.3 State the full meaning of the following:
4.3.1 GALV
4.3.2 PCD
(2 × 1) (2)
4.4 Give THREE types of steel profiles commonly used in metalwork. (3)
[12]
QUESTION 5
5.1 State the function of each of the following machinery:
5.1.1 Horizontal bending rolls
5.1.2 Guillotine
5.1.3 Pedestal drilling machine
5.1.4 Punching machine
5.1.5 Bending press

(5 × 1) (5)
5.2 Mention FIVE safety precautions that should be considered before and during
the use of a pedestal drilling machine. (5)
[10]
QUESTION 6
6.1 State FOUR types of rivet heads used in assembly work. (4)
6.2 Tabulate the formulae used to calculate the following:
6.2.1 Pitch
6.2.2 Landing
(2 × 1) (2)
6.3 Describe the function of each of the following fastening devices:
6.3.1 Black bolts
6.3.2 Countersunk bolts

(2 × 2) (4)
[10]

(11022061) -6- T1080(E)(A16)T
QUESTION 7
7.1 Arrange the following gas welding apparatus in order of its assembly purpose:
7.1.1 Flashback arrestor
7.1.2 Acetylene gas cylinder
7.1.3 Welding torch
7.1.4 Pressure regulator
7.1.5 Welding hose

(5 × 1) (5)
7.2 Without the aid of a sketch, describe the leftward welding technique. (4)
7.3 Mention FOUR factors that would be considered to rectify backfire during gas
welding process. (4)
7.4 Describe how to test for gas leaks during LP-Gas cutting process. (2)
[15]
QUESTION 8
8.1 Define shielded arc welding process. (2)
8.2 List SIX protective clothing that should be worn during arc welding and give
reasons. (6)
8.3 Indicate whether the following statements are TRUE or FALSE. Choose the
answer and write only 'true' or 'false' next to the question number
8.3.1 Slag protects the weld from atmospheric pollution.
8.3.2 Low current results in good welding joint.
8.3.3 Porosity is the result of incorrect welding rod.

(3 × 1) (3)
8.4 State FOUR disadvantages in using a direct current welding machine. (4)
[15]

(11022061) -7- T1080(E)(A16)T
QUESTION 9
FIGURE 2 on DIAGRAM SHEET 2 shows a pipe clamp. The flat bar of 75 mm wide
and 12 mm thick is used to form 40 clamps.
Calculate the length of material required to manufacture 20 clamps. [8]
TOTAL: 100

(11022061) -8- -1- T1080(E)(A16)T
DIAGRAM SHEET 1
FIGURE 1

(11022061) -9- -2- T1080(E)(A16)T
DIAGRAM SHEET 2
FIGURE 2

MARKING GUIDELINE
APRIL EXAMINATION
16 APRIL 2015

METAL WORKER'S THEIORY N1
QUESTION 1
1.1 Unsafe condition
1.3 Unsafe act
1.4 Unsafe act

(5 × 1) [5]
QUESTION 2
2.1 2.1.1 It is used to enlarge the punch mark for drilling or punching.
2.1.2 It is used for general filing work.
2.1.3 It is used for heavy work such as forging, heavy chipping or driving
large pins and shafts into holes.
2.1.4 It is used for cutting metals.
2.1.5 It is used for lining up holes for bolting or riveting.

(5 × 1) (5)
2.2 2.2.1 Outside callipers
2.2.2 Back mark gauge
2.2.3 Sleeve punch
2.2.4 Bevel gauge
2.2.5 Try-square
(5 × 1 (5)
2.3 See the sketches (2)
2.4 R2 = V2 + H2
= (245 mm)2 + (328 mm)2
= 60025 mm2 + 107584 mm2
= √167609 mm2
= 409,4 mm (3)
[15]

QUESTION 3
3.2 C = 3,142 x 32 mm
= 100,54 mm (2)

[10]
QUESTION 4
4.1 4.1.1 Springs, gears, steam and turbines, surgical instruments, bolts and
nuts. (Any 2 × 1) (2)
4.1.2 Gears, gear boxes, cylinder heads, alloy wheels. (Any 2 × 1) (2)
4.2 4.2.1 It is the ability of a metal that allows it to be drawn into a wire
without breaking.
4.2.2 It is the property of the metal that allows it to be stretched without

breaking, by pressure and hammering.
4.2.3 It is the property of metal that determines at what temperature it will

melt.
(3 × 1) (3)
4.3 4.3.1 Galvanised (1)
4.3.2 Pitch circle diameter (1)
4.4 Flat bars, rolled steel joists, universal beams, steel plates, round bars, angle
irons, rolled steel channels. (Any 3 × 1) (3)
[12]
QUESTION 5
5.1 5.1.1 It is used for bending steel plates, round and flat bars
5.1.2 It is used for shearing steel plates
5.1.3 It is used for drilling metals
5.1.4 It is used for punching holes in the surface of metals
5.1.5 It is used for bending steel plates and bars

(5 × 1) (5)

5.2  Wear goggles

 Ensure that the work piece is securely clamped to the drilling table
 Set the machine to the correct working speed
 Do not attempt to stop the drill bit with your hands
 Take note of the position of the emergency stop button or switch
 Lock all the moveable parts of the machine before drilling
 Use a wooden stick to remove the drill shavings from the drill bit
(Any 5 × 1) (5)
[10]
QUESTION 6
6.1  Pan head

 Countersunk head
 Conical head,
 Snap/Cup head (4)
6.2 6.2.1 Pitch = 3 x Diameter
6.2.2 Landing = 1,5 x Diameter

(2 × 1) (2)
6.3 6.3.1 It is used on joints where low stress is experiences such as in

structural work.
6.3.2 It is used where the bolt head is to be set flush or be in line with the
material, and where excessive vibrations are experienced such as
in boilers.
(2 × 2) (4)
[10]
QUESTION 7
7.1 7.1.1 Acetylene gas cylinder
7.1.2 Pressure regulator
7.1.3 Flashback arrestor
7.1.4 Welding hose
7.1.5 Welding torch

(5 × 1) (5)
7.2 Welding is commenced at the right-hand side of the plate and continued
across the plate in a leftward direction. The blow-pipe follows the welding rod.
The torch should be held at an angle between 60 and 70 degrees to the
surface of the plate. The welding rod is held at an angle between 30 and
40 degrees to the surface of the plate. (4)

7.3  Dip an overheated nozzle in the bucket of water

 Clean the dirty nozzle
 Set the welding gases to the correct working pressure
 Check welding hoses for any gas leaks
 Use the correct welding distance between the plate and the nozzle
(Any 4 × 1) (4)
7.4 A mixture of soft soap and water is applied to the tubing or hoses or joints. If
there is a leak the soapy mixture will form bubbles and these bubbles will
identify the leak. (2)
[15]
QUESTION 8
8.1 It refers to all types of electric arc welding where the molten metal is shielded
from the atmospheric by a neutral gas. (2)
8.2  Leather apron protects the body against ultra violet rays and arc rays.
 Overalls for body protection.
 Leather spats for feet protection.
 Leather gloves are used for hands protection.
metals. (Any 6 × 1) (6)
8.3 8.3.1 True
8.3.2 False
8.3.3 True
(3 × 1) (3)
8.4  The generator is complex and has many moving parts which will cause
wear.
 Maintenance costs are much higher on the generator than on the
transformer.
 The generator is considerably more expensive than a transformer
producing comparable welding current.
 Above 200 amperes the magnetic effect of the electric arc created by the
direct current causes the arc-blow. (4)
[15]

QUESTION 9
Mean diameter = 220 + 220 + 12 (1)

= 452 ÷ 2 (1)
= 226 mm (1)
Circumference = 3,142 x 226 mm (1)
= 710,09 mm
Length required for 2 straight pieces (1)
= 66 mm + 66 mm
= 132 mm (1)
Length of material for 1 clamp (0,5)

= 710,09 mm + 132 mm (0,5)
= 842,09 mm
Length of material for 20 clamps
= 842,09 mm x 20 (0,5)
= 16841,8 mm (0,5)
[8]
TOTAL: 100


T1070(E)(N11)T

(11022061)
11 November 2014 (Y-Paper)

13:00–16:00
Drawing instruments and calculators may be used.
This question paper consists of 6 pages and 2 diagram sheets.

(11022061) -2- T1070(E)(N11)T

TIME: 3 HOURS
MARKS: 100
2. QUESTION 3 must be answered on the DIAGRAM SHEET (attached) and

then be handed in.
paper.
6. Show ALL the calculation steps.
7. Use π = 3,142.

(11022061) -3- T1070(E)(N11)T
QUESTION 1
State FIVE safety precautions that must be considered when storing gas cylinders. [5]
QUESTION 2
2.1 Make a neat labelled sketch of a ball-pein hammer. (3)
2.2 Name FOUR characteristics that should be considered when buying a new
file. (4)
2.3 State the use of each of the following marking-off tools:
2.3.1 Measuring tape
2.3.2 Dividers
2.3.3 Bevel gauge
2.3.4 Inside callipers
2.3.5 Scriber
(5 × 1) (5)
2.4 The following measurements will be used to mark-off the right-angled steel
plate:
Hypotenuse side = 365 mm

Vertical side = 246 mm
Calculate the horizontal side of the plate.
HINT: R2 = H2 + V2 (3)
[15]
QUESTION 3
Use DIAGRAM SHEET 1 (attached) to answer this question. Drawing instruments

must be used.
FIGURE 1 DIAGRAM SHEET 1 (attached) shows a T-piece between two equal

diameter steel pipes.
3.1 Draw the line of penetration between the TWO pipes. (2)
3.4 Develop the pattern of the branch pipe. (4)
HINT: C = 3,142 x D
Hand in DIAGRAM SHEET 1 together with the ANSWER BOOK. [10]

(11022061) -4- T1070(E)(N11)T
QUESTION 4
4.1 Distinguish, in tabular form, between mild steel and high-carbon steel with
reference to the following:
4.1.1 Carbon content
4.1.2 Metal properties
4.1.3 Uses
(3 × 2 (6)
4.2 Define the term brittleness. (1)
4.3 Write the abbreviations for the following:
4.3.1 Rolled steel joist
4.3.2 Drawing
4.3.3 Revolutions per minute

(3 × 1) (3)
4.4 Calculate the back mark of the 70 mm × 90 mm × 6 mm channel iron. The

diameter of the hole to be drilled is 10 mm. (2)
[12]
QUESTION 5
5.1 FIGURE 2, DIAGRAM SHEET 2 (attached) shows three machines used in a

metal workshop.
Identify the machines numbered (5.1.1–5.1.3) and state the function of each.
(2 × 3) (6)
5.2 State FOUR safety precautions that should be considered when using the
bending machine. (4)
[10]
QUESTION 6
6.1 Draw neat labelled sketches to describe a single-riveted butt joint with TWO
rivets in position. (2)
6.2 Refer to QUESTION 6.1 above to explain the following:
6.2.1 Snap or cup head rivet (2)
6.2.2 Pitch (1)
6.2.3 Landing (1)

(11022061) -5- T1070(E)(N11)T
6.3 State the function of each of the following fastening devices:
6.3.1 Countersunk bolts
6.3.2 High-carbon steel bolts

(2 × 2) (4)
[10]
QUESTION 7
7.1 Name FIVE safety protective equipment that must be worn during gas welding
and give the reason for each. (5 × 1) (5)
7.2 State the types of the welding flame settings used in the following:
7.2.1 Welding stainless steel
7.2.2 Brazing mild steel

(2 × 1) (2)
7.3 State THREE functions of pressure regulators. (3)
7.4 Briefly explain the procedure that should be followed when welding in a
confined or hidden places using oxy-acetylene gas equipment. (5)
[15]
QUESTION 8
8.1 Explain the following as applied to arc welding and give ONE example of
each:
8.1.1 Insulators
8.1.2 Conductors
(2 × 2) (4)
8.2 Define the following welding terms:
8.2.1 Direct current (2)
8.2.2 Metal inert-gas welding (3)
8.2.3 Straight polarity (2)
8.3 State FOUR advantages of using direct-welding machine. (4 × 1) (4)

[15]

(11022061) -6- T1070(E)(N11)T
QUESTION 9
FIGURE 3, DIAGRAM SHEET 2 (attached) shows the front view of a chain link.
Calculate the length required to form 20 chain links. [8]
TOTAL: 100

(11022061) -7- -1- T1070(E)(N11)T
EXAMINATION NUMBER:
DIAGRAM SHEET 1
FIGURE 1

(11022061) -8- -2- T1070(E)(N11)T
DIAGRAM SHEET 2
5.1.2
5.1.2
5.1.1
5.1.1 5.1.3
5.1.3
FIGURE 2
FIGURE 3

MARKING GUIDELINE
11 NOVEMBER 2014

QUESTION 1
 Cylinders must be stored in a sheltered storeroom.

 They must not be stored in the underground storeroom.
 Both acetylene and oxygen cylinders must be stored separately.
 Empty and full cylinders must be stored separately.
 'No naked flame' sign must be posted where cylinders are stored.
 Empty cylinders must be tightly closed. (Any 5 × 1) [5]
QUESTION 2
2.1
(3)
2.2  Length
 Roughness
 Cut
 Shape (4)
2.3 2.3.1 It is used to measure long lengths from 2 m to 25 m.
2.3.2 It is used to scribe circles, and mark out the pitches of rivet and bolt
holes.
2.3.3 It is used to mark off bevels or miters on steel sections.

2.3.4 It is used to obtain the inside diameter of a hole, a pipe or to obtain

a measurement where it is not possible to use a steel rule.
2.3.5 It is used for marking lines on plates and bars that have been
whitened.
(5 × 1) (5)
2.4 R2 = H2 + V2
H2 = R2 – V2
= (365 mm)2 – (246 mm)2 (1)
= 133 225 mm2 – 60516 mm2 (0,5)
= √72 709 mm2 (0,5)
= 269,65 mm (1)
[15]

QUESTION 3
3.1
(2)

3.2 C = 3,142 x 36 mm
= 113,11 mm (2)

[10]
QUESTION 4
4.1 MILD STEEL HIGH CARBON STEEL

4.1.1 Carbon Between 0,1% and Between 0,8% to 1,0% (1)
content 0,3%
4.1.2 Metal Malleable, ductile, Hard, brittle, tough, elastic,
properties elastic, tough, fusible
4.1.3 Uses Used in the Used in the manufacturing of

manufacturing of steel shear blades, coil springs, knife
plates, bars, angle blades, twist drills, metal cutting
irons, channel irons, tools, files.
H-beams, rivets, bolts
and nuts.
(3 × 2) (6)
4.2 It is the metal's ability to withstand an impact without breaking. (1)
4.3 4.3.1 RSJ
4.3.2 DRG
4.3.3 RPM
(3 × 1) (3)
4.4 Back mark = (70 + 12) mm (0,5)

= 82 mm ÷ 2 (0,5)
= 41 mm (1)
[12]

QUESTION 5
5.1  Pedestal drilling machine is used for drilling holes on the surface of metals.
 Horizontal bending rolls is used for bending steel plates and bars.
 Guillotine is used for shearing steel plates. (2 × 3) (6)
5.2  Avoid fingers from getting trapped in the machine blades

 Wipe off any oil or grease on the metal before bending
 Under no circumstances must the machine be overloaded
 Take note of emergency stop button or switch
 Ensure that all guards are in position before operating the machine
(Any 4 × 1) (4)
[10]
QUESTION 6
6.3 6.3.1 It is used where the bolt head should be set flush or be in line with
the plate, and used where excessive vibration occurs such as in
boilers.
6.3.2 It is used where excessive vibration occurs such as in engines.

(2 × 2) (4)
[10]
QUESTION 7
7.1  Leather apron protects the body against hot welding flames.
 Overalls for body protection.
 Leather spats for feet protection.
 Leather gloves are used for hands protection.
metals.
 Welding goggles for the protection of the eyes. (Any 5 × 1) (5)
7.2 7.2.1 Neutral flame
7.2.1 Oxidising flame

(2 × 1) (2)
7.3  It allows for pressure adjustments

 It keeps pressure constant
 It reduces the high pressure of the gas in the cylinder to an operating
pressure suitable for welding. (3 × 1) (3)

7.4  Keep the cylinders outside the confined space.

 Let there be one person to operate the cylinders outside.
 Keep the fire extinguisher handy
 Light the torch outside before entering the confined space.
 Ensure that there is enough ventilation.
 Check for gas leaks on the hoses. (Any 5 × 1) (5)
[15]
QUESTION 8
8.1 8.1.1 Insulators are materials which do not allow electric current to flow
in it. Examples: wood, PVC, glass, rubber, (etc)
8.1.2 Conductors are materials which allow electric current to flow in it.
Examples: copper, silver, iron, aluminium, (etc)
(2 × 2) (4)
8.2 8.2.1 It is a current which flows in one direction only. (2)
8.2.2 Metal inert gas welding consists of a transformer, an inert gas such
as argon, helium or carbon and the welding gun. (3)
8.2.3 It is the term used when the electrode holder is connected to the
negative pole and the metal being welded connected in to the
positive pole in the direct current welding machine. (2)
8.3  Almost all commercial available welding rods can be used with the direct
current generator.
 The motor generator is not affected by current fluctuations in the power
supply and a stable current can be maintained.
 Cast iron and aluminium can only be welded successfully with the direct
current generator.
 The polarity between the electrode holder and the work being done can be
changed to direct the greater heat to either the electrode or work. (4 × 1) (4)
[15]
QUESTION 9
Chain link:
Length required for two straights:

150 mm x 2 = 300 mm
Length required for the two semi-circles:
Circumference = 3,142 x 70 mm
= 219,94 mm
Total length = 300 mm + 219,94 mm
= 519,94 mm
For 20 links: 519,94 mm x 20
10398,8 mm or 10,399 m [8]


TOTAL: 100

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EKURHULENI TECH COLLEGE.

No. 5 Mogale Square, Krugersdorp.

METAL WORKERS THEORY

Website: www.ekurhulenitech.co.za Email: [email protected]

METAL WORKERS' THEORY N1

17 November 2016 (X-Paper)

Candidates need drawing instruments

This question paper consists of 7 pages and 1 addendum.

Copyright reserved Please turn over

DEPARTMENT OF HIGHER EDUCATION AND TRAINING

INSTRUCTIONS AND INFORMATION

1. Answer ALL the questions.

2. Read ALL the questions carefully.

3. QUESTION 3 must be answered on the ADDENDUM and handed in.

6. Keep ALL the subsections of questions together.

7. Show ALL the calculation steps where necessary.

8. Write neatly and legibly.

Copyright reserved Please turn over

List FOUR tasks where goggles must be worn. (4)

2.1 Hand chisels have their own cutting action.

2.1.1 List THREE types of hand chisels. (3)

2.2 State ONE use of the following hand tools:

2.2.1 Ball-peen hammer

2.2.2 Sleeve punch

2.2.3 Cross-cut file

2.2.4 Tapered drift

Copyright reserved Please turn over

3.1 Draw the given view. (2)

3.3 Develop the pipe marked A. (3)

3.4 Develop the pipe marked B. (3)

4.1 Define the following properties of a metal:

Copyright reserved Please turn over

5.2 What do the following abbreviations stand for?

6.3 State ONE function of each of the following machines:

6.3.1 Circular power saw

6.3.2 Radial-arm drilling machine

6.3.3 Bending press

Copyright reserved Please turn over

7.3 Name FOUR types of bolts commonly used in an assembly. (4)

7.4.1 Flat washer

7.4.2 Spring washer

7.4.3 Taper washer

Copyright reserved Please turn over

8.3 Name THREE oxyacetylene welding flame settings. (3)

9.1 Explain the following welding terms:

9.1.1 DC welding machine (1)

9.1.2 Earthing (2)

9.1.3 Reverse polarity (2)

9.3 List THREE disadvantages of using an alternating-current welding machine. (3)

Internal diameter of the cylinder is 770 mm

Calculate the following:

10.1 The length required to form the internal cylinder.

ADDENDUM EXAMINATION NUMBER:

This marking guideline consists of 7 pages.

Copyright reserved Please turn over

1.1  When emery wheels are used.

1.2 Electric shock will occur. (1)

2.1 2.1.1  Flat/chipping chisel

2.2 2.2.1 It is used for light riveting work.

2.2.2 It is used when a large number of items are to be marked from a