1

Western Cape Education Department

Directorate: Curriculum FET

MECHANICAL TECHNOLOGY
WELDING AND METALWORK
TERM 1
REVISION BOOKLET
Grade 11
2023
This revision program is designed to assist you in revising the content and skills covered
during the First term. The purpose is to prepare you to understand and grasp the key
concepts and provide you with an opportunity to consolidate the knowledge necessary
to do well in your assessments.
The revision program covers the following topics:

INDEX PAGE

Term 1. Content Page number

1 SAFETY (GENERIC) 3-5

2 TERMINOLOGY (SPECIFIC) 6-7

3 TOOLS (SPESIFIC) 8 - 11

4 GENERAL

There are also lessons on various Gr 11 topics on the WCED e-Portal

(https://wcedeportal.co.za/)

Final examination: At the end of each academic year learners are required to write a final
examination, which is compiled in such a way that it represents the entire theoretical
content covered throughout the year. The final examination accounts for 50% of the
learner’s promotion mark. Below is a table of Bloom’s taxonomy indicating the action
verbs and also gives you the cognitive level of the learners’ ability. Learners can expect
different levels of questioning.
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MECHANICAL TECHNOLOGY - BLOOM'S TAXONOMY:
Knowledge: memorize and recall information: arrange, define,
Lower order label, list, outline, repeat, order 30%
Comprehension: (understanding) — interpret information in one’s
own words: describe, indicate, restate, review, summarize, classify
Application: apply knowledge to new situations: apply, calculate,
Medium draw, explain, identify, illustrate, prepare, operate, practice,
Order solve, sketch, use 50%
Analysis: breakdown knowledge into parts and show relationship
among parts: analyse, categorize, compare, distinguish, discuss,
examine, investigate, and test
Synthesis: bring together parts of knowledge to form a whole;
build relationships for new situation: arrange, compose,
High Order formulate, organize, plan, assemble, construct 20 %
Evaluation: make judgments on basis of criteria: appraise, assess,
comment on, critically analyse, evaluate, conclude, interrogate,
judge, predict, compare, and score

PROGRAMME OF ASSESSMENT
School-based Assessment - SBA Practical Assessment Task - PAT Final Examination
25% 25% 50%

TIME in
QUESTION CONTENT MARKS
minutes
GENERIC
1 Multiple-choice questions 6 6
2 Safety 10 10
3 Materials 14 14
SPECIFIC
4 Multiple-choice questions 14 10
5 Terminology (Templates) 23 20
6 Tools and Equipment 18 15
7 Forces 45 30
8 Joining Methods (Inspection of Welds) 23 20
9 Joining Methods (Stresses and Distortion) 18 20
10 Maintenance 9 10
11 Terminology (Development) 20 25
TOTAL 200 180
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WELDING AND METALWORK
TERM 1
TOPIC 1 SAFETY (Generic)
HIV/AIDS Awareness
Knowledge of basic First Aid measures
Analyse the OHS Act and regulations where applicable to the following machines:
• Grinding machines (portable, bench and surface)
• Cutting (drilling machines, power saw, band saw)
• Shearing machines (manual and power driven)
• Press machines
• Joining (arc, gas)
• Handling and usage of gas cylinders
SAFETY (GENERIC)
Safety rules to be observed before a hydraulic An angle grinder is used to smoothen a
press is used. welded joint. Safety measures to be
• Make sure the press is in a good working observed before using the angle grinder.
condition. • Do not use excessive force while
• Take notice of the pre-determined maximum grinding
pressure of the hydraulic press. • Ensure that the sparks do not endanger
• Make sure the area around the press is clean co-workers
and free of oil, grease and water. • Keep hands clear from grinding disc
• Ensure that the platform is rigid and square to • Maintain a firm grip on the angle
the cylinder. grinder
• Ensure that suitable jigs and prescribed Note: Examiner may ask before, after or
equipment is available during use of the equipment.

Safety precautions that should be considered before and during the use of a pedestal drilling
machine.
• 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
• Adjust the machine to the correct working speed
• Clamp the workpiece properly
• Use the coolant during the drilling process
• One person at a time to operate the machine

Reasons for wearing surgical gloves when treating a co-worker with open wounds.
• To prevent HIV/AIDS or any blood related infections being transmitted.
• To prevent contamination of the open wounds.
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Safety precautions to be considered during Safety precautions to be considered during
the use of the Bending press: the use of the Pedestal grinding machine:
• Avoid fingers from getting trapped in the • Wear goggles.
press. • Check the grinding wheel for any cracks.
• Do not overload the machine. • Set the tool rest to the correct distance.
• Wipe the plates from oil or grease. • Keep the machine guards in position.
• Take note of emergency switches. • Avoid playing around.
• Ensure that all guards are in position

Items of personal protective equipment (PPE) Reasons why you need to clamp down a
that one will use when working with a small work piece before any drilling is done.
hydraulic press. • To prevent injuries.
PPE for Hydraulic press: • To improve accuracy.
• Overall • To prevent work piece rotating/moving
• Safety shoes
Safety rule that must be adhered to before
• Safety goggle
any machine in the workshop is switched on.
• Leather gloves
Know how and where to switch the machine
• Leather apron
off/stop.
• Face shield

Safety rules to be observed when using the hydraulic press.

• Predetermined pressure must not be exceeded.
• Pressure gauge must be tested regularly and replaced if malfunction occurs.
• The platform must be rigid and square to the cylinder.
• Objects to be pressed must be placed in suitable jigs.
• Ensure that the direction of pressure is always at 90° to the object.
• Only prescribed equipment must be used.

Safety precautions to be observed when working with each of the following machines:
Guillotine
• Do not make any adjustments to the guillotine while it is in operation.
• Wear safety gloves to protect your hands against sharp plate edges.
• Keep your fingers away from the moving guillotine blades.
• Only one person at a time may operate the machine.
• 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.

Pedestal grinder
• Always wear safety grinding goggles when grinding.
• Do not bump the material against the grinding wheel while it is rotating.
• Make sure the gap between the wheel and the rest is not more than 3 mm
• Allow the grinding wheel to reach working speed before use.
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Horizontal bending rolls:
• Do not overload the machine.
• The steel profile to be bent must be free from any oil or grease.
• Ensure that the rolls are clean and free from grease or oil.
• Check that the plate or bar to be rolled is securely held or supported.
• Ensure that the area around the rolling machine is clear.
• Avoid fingers from getting trapped into the rollers.
• Avoid wearing any loose or hanging clothing.
The responsibilities of the employer regarding first aid in the workplace.
• Provision of first-aid equipment
• First aid training
• First-aid services by qualified personnel
• Any first aid procedures
• Display first aid safety signs
• First aid personnel must be identified by means of arm bands or relevant personal signage.
The responsibilities of the employee Safety precautions to be observed for the safe
regarding safety in the workplace. handling of portable electrical equipment.
• Pay attention to their own and other • Ensure the electrical cord is in a good
people’s health and safety. condition.
• Co-operate with the employer regarding • Ensure that plug is wired properly and/in a
the OHS Act. good condition.
• Carry out a lawful order given to them. • Ensure all safety guards are in place.
• Report any situation that is unsafe or • Ensure that the attachments (drill bits, blades
unhealthy. etc.) are fixed in the correct way.
• Report all incidents and accidents. • Do not force the machine/equipment.
• Not to interfere with any safety equipment • Operate according to manufacturer
or misuse such equipment. instructions.
• Obey all safety rules.
The employer's responsibility regarding Reasons why it is important to wear welding
equipment in the workplace. goggles during oxy-acetylene gas welding.
• They must provide and maintain • To protect your eyes from the spatter
equipment • To protect your eyes from the harmful rays
• Ensure that the equipment is safe to use • To ensure proper vision of the process
by employees Personal protective equipment (PPE) that one will
• Provide safe storage for equipment use when working with a bench grinder.
• Provide proper training of employees in • Overall
the use of the equipment • Safety goggles
• Enforce safety measures • Safety shoes
Goggles are safety equipmentand must be worn to protect the eyes when doing the following
tasks:
• When emery wheels are used.
• When a chipping hammer is used.
• During oxy-acetylene gas welding.
• When hitting brittle material such as welding slag or removing rust from plates.
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Define an accident.
It is an unplanned and uncontrolled incident which is caused by unsafe acts or unsafe
conditions that results in or has a potential for physical harm to persons or property damage.
ACTIVITY
1. State the safety precauations that must be considered during the use of each of the
following machinery:
1.1.1 Pedestal grinding machine
1.1.2 Pedestal drilling machine
1.1.3 Bending press
1.1.4 Bending Rolls
1.1.5 Reciprocating power saw
2. State the function of each of the following machinery:
2.1.1 Horisontal bending rolls
2.1.2 Bending rolls
2.1.3 Pedestal drilling machine
2.1.4 Guilotine
2.1.5 Angle grinder
2.1.6 Hydraulic press
3. Mention the safety precautions for arc and spot welding.
4. After welding a joint it needs to be grinded with an angle grinder to obtain a smooth
surface. Name the safety measures to observe before switching on the angle grinder.
5. State the safety rules to apply when using a portable hand drill machine.
6. What safety rule must be adhered to after working procedures on any machine have
been completed?
7. State THREE safety rules one must adhere to before switching on the horizontal band saw.
8. What safety precaution should be adhered to when drilling a small work piece on a drill
press?
9. State the safety rules to be observed when using a hydraulic press.
10. What is the function of a tap and die set?
11. What is the difference between a power saw and a horizontal band saw?
12. Describe the use of a pedestal grinding machine.
13. The FIGURE below shows a type of cutting machine. Answer the questions that follow.
 7
TOPIC 2 TEMPLATES (SPECIFIC)
• Materials used for templates: wood, cardboard, steel plate and hardboard
• Principle of simple setting out of the right angle and the application of Pythagoras
theorem, the ratio of 45° and 60° right angled triangles.
• Use principles 3, 4 and 5
• Standard cross centres and backmarks
• Transference of floor diagrams to templates
• Use of strip, flange and web templates for steel sections. Ordinary and bushed
steel templates.
• Use of coloured and lettered holes, instructions and conventional marks on templates.

THE APPLICATION OF ROOF TRUSSES: - CALCULATIONS OF:

• Rise
• Slope
• Pitch
The layout of roof trusses, details of purlins, truss shoes, wall plates, expansion and footing.
CALCULATION OF COSTS:
• Quantification from drawings
• Compiling of cutting lists
• Calculation of cost of roof trusses and lattice beams

EXPLAIN THE FOLLOWING TERMINOLOGY:

• Deposited metal • Kerf
• Fusion zone • Spatter
• Gap • Weld pool
• Heat effected zone

WELDING SYMBOLS:
• Fusion weld symbols • Supplementary symbols

Abbreviation: The purpose of purlins as used on roof trusses.

• O.S.U - Other Side Up • The purlins support the roof covering.
• TSU - This Side Up • Stabilizes the trusses.
• GALV - Galvanised The uses of templates.
• RPM – Revolution per minute • Templates are used to avoid repetitive
• Setting out point - SOP marking off the same dimensions.
• Rolled steel channels – RSC • To avoid unnecessary wastage of material.
• Universal beam - UB
Pitch: It is the distance measured from the Landing:
centre to the next centre point of the It is the distance measured from the edge to
rivet/bolt. (3 x Ø) the centre point of the rivet/bolt. (1 x Ø)
Thin sheet metal: Hardboard: Template for gusset plate to be
Up to 3 mm plate can be used for profile produced in small quantities. Sizing and
cutting machines. checking purposes.
 8
Calculate the back mark of a What is the value of X indicated in the FIGURE
50 mm x 50 mm x 6 mm angle iron. below?
Answer: Select the correct one.
Back mark = 50 mm + 6 90 mm
= 56 mm ÷ 2(0.5) 60 mm
= 28 mm 30 mm
120 mm
A steel ring with an outside diameter of 880 mm Plate girder:
must be fabricated from a 50 x 50 mm square as used on a beam is a combination of
steel bar. Calculate the dimensions of the plates and angle iron welded together.
required material. Reasons why the template loft is separated
• Meandiameter (θ) = Outside diameter - from the workshop in most cases.
platethickness The template loft is separated from the
• Meanθ = 880mm - 50 mm workshop because…
• Meanθ = 830mm • it is quieter.
• Mean circumference = π x Meanθ • the lighting is better.
• Mean circumference = π x 830 mm • all equipment is at hand.
• Mean circumference = 2607,2mm • it is a permanent base.
• 2608mm of 50 x 50mm square steel bar is • marking on the floor enhance accuracy.
required to fabricate the ring.
The purpose of supplementary weld symbols? Calculate the back mark of a 50 mm x 50
• To indicate the additional information about mm x 6 mm angle iron.
the weld. Back mark = 50 mm + 6
• To indicate the supplementary information = 56 mm ÷ 2(0.5)
about the weld. = 28 mm
Calculate the hypotenuse of a right-angled triangle with the following measurements:
The vertical side = 245 mm
R² = V² + H²
The horisontal side = 328 mm
= (245 mm) ² + (328 mm) ²
= 60025 mm² + 107584 mm²
= √67609 mm²
= 409,4 mm
The outside diameter of a cylinder is 670 mm made from a 6 mm thick steel plate. The cylinder is
secured with a 10 mm thick stiffening ring. Calculate the length of the material required to form
the cylinder.
Cylinder: Stiffening ring:
Mean diameter = 670 mm — 6 mm Mean diameter = 670 mm + 12 mm + 10 mm
= 664 mm = 692 mm
Circumference = 3,142 x 664 mm Circumference = 3,142 x 692 mm
= 2086,29 mm = 2174,26 mm
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THE APPLICATION OF ROOF TRUSSES:

The FIGURE below indicates a roof truss. Label parts A–E.

• A – Purlin
• B – Rafter
• C – Incline tie
• D – Tie beam
• E – Shoe plate/Gusset plate

A mild steel ring with an outside diameter of 300 mm must be fabricated from a 60 x 20 mm
rectangular plate, as shown below. Calculate the dimensions of the material required to
fabricate the steel ring.
Answer:
Meandiameter(ø) = Insideø + Thickness
= 215 + 20
= 235mm
Mean circumference = π x Meanø
= π x 235
= 738,27mm
Round off to = 740mm

The FIGURE below shows a roof truss. Label parts A to E.

Roof truss:
A – Principal rafter
B – Cleat
C – Purlin
D – Internal bracing members
E – Gusset plate

The FIGURE below shows a simple roof truss. Label A–E.

Part of roof truss:

A. Tie beam
B. Rafter
C. Ridge
D. Rise
E. Span

Describe the function of the countersunk bolts.

It is used where the bolt head is set flush or be in line with the metal and where excessive
vibration occurs.
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The Figure below shows a simple joint of a riveted Queen truss. Use a scale of 1: 1 to lay out the
joint and draw the gusset plate. Show only the position of the rivets. The purlin marked (A)
consists of 40 x 40 x 5 LS with a back mark of 23 mm and pitches of 3d. Both the main girder
marked (C) and the collar beam marked (B) are made from 30 x 30 x 3 LS with a back mark of
17 mm and pitches of 3d. The rivets used on the girder and collar beam are 12 mm in diameter.

Question Answer.

(17)
A mild steel ring must be manufactured using a 16 x 16 mm square mild steel bar. The inside
diameter of the ring is 230 mm.
Calculate the dimensions of the material needed to manufacture the ring.
Draw a neat sketch indicating the dimensions needed for the calculations.
Answer:
Mean Ø = inside Ø + thickness
= 230 + 16 mm
= 246 mm
Mean circumference = π x mean Ø
= π x 246
= 772,83 mm
Rounded off to 773 mm

The internal diameter of a mild steel plate with a 10 mm thickness is 864 mm.
1. Calculate the length of material required to form the cylinder.
2. Calculate the length of the external stiffening ring when a 12 mm round bar is used.
The cylinder:
Mean diameter: = 864 mm + 5 mm + 5 mm
= 874 mm
Circumference: = 3,142 x 874 mm,
= 2746,11mm
The external stiffening ring: Circumference
Mean diameter: = 3,142 x 896 mm
= 864 mm + 10 mm + 10 mm = 2815, 23 mm
= 884 mm + 12 mm
= 896 mm
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CALCULATION OF COSTS:
Figure below shows a line diagram of a steel framework. The framework is welded and consists
of single-angle profiles without gusset plates. The total time taken to manufacture one
framework is 9 hours, at a tariff of R280,00 per hour, while the overhead costs are calculated at
95% of the material cost.
The cost of the 80 x 80 x 8 mm angle profiles marked A and B with a mass of 8,8 kg/m length is
R5,70 per kilogram and the 60 x 60 x6 mm profiles marked C and D with a mass of 6,49 kg/m
length is R4,35 per kilogram. An amount of R250,00 is allocated for welding material per
framework.

Answers are in red

No req. Material req. in M Total Total mass TARIFF
Mark Amount
Mass/kg /kg /kg
A 1 10 m 8.8 kg/m 88 kg R5,70 /kg R501.60

B 2 11,6 m 8.8 kg/m 102.08 kg R5,70 /kg R582.15

C 2 6,8 m 6,49 kg/m 44,132 kg R4,35 /kg R191.97

D 2 3,4 m 6,49 kg/m 22,066 kg R4,35 /kg R95,99

Welding material R250.,00

Total cost R1 621,71

Copy the above table in your answer book and calculate the total material cost. (18)

Calculate the labour cost. Calculate the overhead Calculate the total
cost. cost.
= Tariff per hour x hours worked
= R280 x 9 hours = % allowed x labour cost = material cost + labour cost +
= R2520.00 = 95/100 x R1 621,71 overhead cost
= R1 540,62 = R1 621,71 + R2 520,00 +
R1 540,62
= R5 682,33
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functions of the following machinery:
Horizontal bending rolls - It is used for bending steel plates, round and flat bars
Guillotine - It is used for shearing steel plates
Pedestal drilling machine - It is used for drilling metals
Punching machine - It is used for punching holes in the surface of metals
Bending press - It is used for bending steel plates and bars.
Circular power saw - It is used for cutting heavy steel profiles such as I-beams, angle iron, etc.
Radial arm drilling machine - It is used for drilling steel sections.
Horizontal bending rolls - it is used for bending steel plates and bars.

Safety precautions that must be considered during the use of each of the following machinery:
Guillotine Pedestal grinding machine
• Do not make any adjustments to the guillotine • Wear goggles.
while it is in operation. • Check the grinding wheel for any cracks.
• Wear safety gloves to protect your hands • Set the tool rest to the correct distance.
against sharp plate edges. • Keep the machine guards in position.
• Keep your fingers away from the moving • Do not bump the material against the
guillotine blades. grinding wheel while it is rotating.
• Only one person at a time may operate the • Make sure the gap between the wheel
machine. and the rest is not more than 3 mm
• Adjust the machine to the correct size of the • Allow the grinding wheel to reach
plate to be sheared. working speed before use.
• Under no circumstances may a machine be Horizontal bending rolls:
overloaded. • Do not overload the machine.
• Ensure that the machine blades are in good • The steel profile to be bent must be free
working condition from any oil or grease.
• Wipe off any grease or oil on the plate to be • Ensure that the rolls are clean and free
cut from grease or oil.
• Remove any obstructive object behind the • Check that the plate or bar to be rolled is
machine. securely held or supported.
• One person at a time to operate the machine • Ensure that the area around the rolling
• Avoid fingers from getting trapped beneath machine is clear.
the plate to be cut. • Avoid fingers from getting trapped into
Bending press the rollers.
• Avoid fingers from getting trapped in the press. • Avoid wearing any loose or hanging
• Do not overload the machine. clothing.
• Wipe the plates from oil or grease.
• Take note of emergency switches.
• Ensure that all guards are in position.
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Safety precautions that should be considered before and during the use of a pedestal drilling
machine.
• 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
• Adjust the machine to the correct working speed
• Clamp the workpiece properly
• Use the coolant during the drilling process
• One person at a time to operate the machine.
ROLLING AND BENDING
The heel diameter of a 100 mm × 100 mm × 12 mm internal angle-iron ring is 1,8 m.
Use the following formula:
L = [D – T – (T ÷ 3)] × π
Where L = Length of angle iron
D = Heel diameter of angle-iron ring
T = Thickness of angle iron
Calculate the length of the angle iron required to form the ring.
L = (D – T – T ÷ 3) × 3,142
= (1 800 – 12 – 12 ÷ 3) × 3,142
= (1 784) × 3,142
= 5 605,328 mm
The internal diameter of a cylinder is 670 mm made from a 6 mm thick steel plate. The cylinder is
secured with a 10 mm thick stiffening ring.
Calculate the length of the material required to form the cylinder.
Calculate the length of a round bar to form a stiffening ring.
Cylinder:
Mean diameter: = 670 mm - 6 mm = 664 mm
Circumference: = 3,142 x 664 mm
= 2086,29 mm
Stiffening ring:
Mean diameter = 670 mm + 12 mm + 10 mm = 692 mm
Circumference = 3,142 x 692 mm
= 2174,26 mm
State FOUR types of rivet heads used in assembly work.
• Pan head
• Countersunk head
• Conical head,
• Snap/Cup head
 14

WELDING TERMINOLOGY:
Arrange the following gas welding apparatus in order of its assembly purpose:
1.1.1 Flashback arrestor Acetylene gas cylinder
1.1.2 Acetylene gas cylinder Pressure regulator
1.1.3 Welding torch Flashback arrestor
1.1.4 Pressure regulator Welding hose
1.1.5 Welding hose Welding torch

Arrange the following list of gas apparatus in order of sequence, as applicable to the
oxy-acetylene gas-welding assembly process.
1.1.6 Flash-back arresters Gas bottles
1.1.7 Welding torch Pressure regulators
1.1.8 Pressure regulators Flash back arresters
1.1.9 Gas bottles Welding hose
1.1.10 Welding hose Welding torch

Without the aid of a sketch, describe the leftward welding technique.

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° to the surface of the plate.
The welding rod is held at an angle between 30° and 40° to the surface of the plate.
Factors that would be considered to rectify backfire during gas welding process.
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.
The types of the welding flame settings used to do the following:
Welding stainless steel - Neutral flame
Brazing mild steel - Oxidising flame
Testing for gas leaks during oxy-acetylene cutting process.
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.
Functions of the pressure regulators on the oxy-acetylene cylinders.
It determines the pressure inside the cylinder and the working pressure in the hoses.
Draw a labelled sketch of a leftward-welding technique.
Causes of backfire during the gas cutting process.
Overheated nozzle. Dirty nozzle.
Incorrect gas setting. Holding the welding torch too close to the
Incorrect cutting speed workpiece.
Empty gas bottles. Unequal amounts of gasses

How to extinguish the oxy-acetylene gaswelding flame.

The flame is extinguished by first closing the LP-gas and then the oxygen gas.
 15
Reasons why regulators should be slowly opened.
To avoid damaging the regulator valves as this may result in an explosion.
Functions of pressure regulators.
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.
Welding hose
It transports the gas from the cylinder to the welding/cutting torch
Oxygen pressure gauge
It regulates the flow of the oxygen gas leaving the cylinder to the welding hose
Acetylene flash back arrestor
It is used to prevent the burning gas entering back into the cylinder
Welding torch
It is used for cutting metal.
Cutting torch
It is used for cutting steel profiles.
Aspects to consider when rectifying backfire.
Clean the dirty nozzle.
Keep a suitable cutting distance between the workpiece and the welding torch.
Avoid using empty gas cylinders.
Test welding hoses for any leaks.
Make a neat sketch of a weld symbol indicating the following information on a T-joint done with
arc-welding:
The intermittent fillet weld on both sides is 6 mm in size.
The lengths of the weld beads are 40 mm each.
The pitch of the weld is 90 mm.
Answer: ✓
Ar ✓
✓ 6✓ ✓ ✓ 40 –90
✓ ✓

Identify the TWO dimensions of the weld as shown in FIGURE 5.7 below.

• 30°- an included angle in degrees

• 3- root gap or root opening in mm

Identify the following resistance weld symbols: Name examples of fusion welds.
• Spot
Spot weld • Projection
• Seam
• Foil seam
Seam weld • Flash or resistance butt
 16
The FIGURE below shows a welding symbol. Label parts A–F. Welding symbols:
• A. Tail
• B. Weld symbol (Fillet weld)
• C. Pitch of weld
• D. Site weld
• E. Arrow
• F. Weld all round
Spot welding equipment
This method uses the heating effect, which occurs when a current flow through a resistance, to
fuse two plates together.
Regulators on gas cylinders:
• Regulators: reduce the cylinder pressure to operating or working pressure.
• Flashback arrestors: it works a non-return valve and prevents the gases from flowing back to
cylinders.
• Blowtorch: it mixes the oxygen and acetylene gases together.
Sketch of a shielded arc welding process. The MIG/MAGS welding process. Label A–D.

A – Weld pool / weld bead / molten metal.

B – Electrode wire / electrode
C – Gas shroud /electrical contact /nozzle /
contact tip
D – Shielding gas

WELDING SYMBOL:

Welding finnishing off symbols:

 17
TOPIC 3 Tools (Specific)
The principles and functions of the following purpose-made tooling and equipment:
• Stocks and dies (characteristics and drill sizes)
• Grinding machines (portable, bench)
• Cutting machines (drilling machines, power saw, horizontal band saw)
• Guillotine machine (manual and power driven)
• Press machines
• Joining equipment (arc, spot, gas)
• Rolling machine
• Punch and cropper machine
• Plasma cutter
• Cut –off machine
4. TOOLS AND EQUIPMENT (SPECIFIC)
The working/operating principle of the following machines used in the welding workshop:

Power saw (Reciprocating) Manual guillotine

• The blade is tensioned in the frame and cuts • This guillotine is operated by a foot pedal that
in a forward stroke and the blade is lifted in activates a pressure plate/blade guard and
the backward (reciprocating) motion. then the carbon steel shearing blade cuts the
• The blade assembly is raised and lowered by material.
hydraulic controls to ensure that the cutting • The cut material is ejected at the back of the
pressure is always optimum. machine.
• This prevents the blade from overheating • Extension bars lengthen the work surface and
and binding or breaking. support longer pieces of material.
• The metal section being cut is held firmly in • The calibrated bars can be adjusted to a set
the stock clamp during the cutting process distance if repeat cuts of the same size are
required.
Bending rolls Guillotine
• A bending roll has two fixed rollers next to each • A bottom cutting blade is fixed
other rotating in unison (Manually or Electrical horizontally.
motor). • With a top cutting blade moving
• A third roller is adjustable, moving in between downwards.
the two rollers. • It is driven by an electric motor, flywheel,
• The third roller applies downward pressure onto gearbox and axle by eccentric motion /
the metal. action / hydraulic action. OR
• That causes the metal to deflect and ultimately • It is activated manually by foot with lever
form the round shape desired. action.
Types of material that can be cut with a plasma The different uses of the bench grinder.
cutter. • To sharpen tools and drills.
• Mild steel • It is also used for removing rough edges
• Alloy steels • Removing excess material.
• Stainless steels Types of rolling machines:
• Non-ferrous metals • Horizontal pyramid rolls
• Off-set pinch rolls
• Vertical rolls
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Punch and shear machine. Plasma cutter.
• A shear and punch machine is a heavy-duty • The basic cutting process involves creating an
machine for cutting steel profiles and electrical channel of ionised gas; that is
punching holes into steel plates. plasma, from the plasma cutter itself through
• Croppers are electrically driven and make the work piece that is being cut. Thus, forming
use of a heavy flywheel and clutches to a completed electric circuit back to the
engage various shearing blades to plasma cutter via a grounding clamp.
shear/punch different profiles. • This is accomplished by compressed air that is
• Punches and corresponding dies need to be blown toward the work piece through a
set to the desired size before punching. focused nozzle at high speed.
• They do not require cooling fluid because • A high frequency, electrical arc is then
the shearing action does not develop a formed within the gas between an electrode
great deal of heat. near or integrated into the gas nozzle and the
work piece itself.
Horizontal pyramid rolls
• The rollers are arranged so that, when viewed from the side, they give the impression of a
pyramid.
• All rollers are mounted in a horizontal position, with the bottom two fixed and rotating in unison.
• The top roller is adjustable (up or down); applying downward pressure on the metal plate being
rolled that will cause it to deflect and form the round shape.
• When rolling a cylinder, it is of critical importance to ensure that the top roller is always adjusted
parallel to the lower roller to guarantee a uniform cylindrical shape.

The use of the press machine in the mechanical workshop?

• The press machine is used for installing or removing components on mechanical devices /
machines.
• To press profiles onto material

General comments on the answering of questions

1. Leaners must always start each question on a new page as indicated in the instructions.
2. Learners have difficulty expressing themselves when responding to describe/explain type
of questions. It is important to explain/describe concepts in a logical sequence.
3. Learners should be careful not giving general responses that are incorrect instead of
specific responses. E.g. learners responded by indicating that workers should wear PPE
instead of a specific item, like safety goggles.
4. In a question that counts two marks, learners only provided one response instead of two.
Learners must provide answers inline with the mark allocation of the question.
5. Learners should not only rely on activities that are in the textbooks but alternative
questions on all cognitive levels for all the topics and should consult past question papers
6. Learners must work do all the topics and all the activities to make sure consolidation and
understanding.
7. Ensure that you write down the correct units and lable the drawings correctly.