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 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.

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(11022061) -2- T1000(E)(N17)T

DEPARTMENT OF HIGHER EDUCATION AND TRAINING

REPUBLIC OF SOUTH AFRICA
NATIONAL CERTIFICATE
METAL WORKERS' THEORY N1
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.

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(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]

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(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]

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(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]

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(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)

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(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

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(11022061) T1000(E)(N17)T

ADDENDUM EXAMINATION NUMBER:

QUESTION 3

Copyright reserved
 MARKING GUIDELINE

NATIONAL CERTIFICATE
NOVEMBER EXAMINATION
METAL WORKERS' THEORY N1

17 NOVEMBER 2016

This marking guideline consists of 7 pages.

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MARKING GUIDELINE -2- T1000(E)(N17)T
METAL WORKERS' THEORY N1

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]

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 MARKING GUIDELINE -3- T1000(E)(N17)T
METAL WORKERS' THEORY N1

QUESTION 3
3.1

(2)

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MARKING GUIDELINE -4- T1000(E)(N17)T
METAL WORKERS' THEORY N1

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]

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MARKING GUIDELINE -5- T1000(E)(N17)T
METAL WORKERS' THEORY N1

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)

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MARKING GUIDELINE -6- T1000(E)(N17)T
METAL WORKERS' THEORY N1

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)

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MARKING GUIDELINE -7- T1000(E)(N17)T
METAL WORKERS' THEORY N1

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
 EKURHULENI TECH COLLEGE.
No. 5 Mogale Square, Krugersdorp.
Website: www.ekurhulenitech.co.za
Email: info@ekurhulenitech.co.za
TEL: 011 040 7343 CELL: 073 770 3028

ABOUT THE QUESTION PAPERS: THE COST PER SUBJECT IS R300.

ABOUT REGISTERING WITH OUR COLLEGE

CONSIDER REGISTERING WITH OUR COLLEGE AND WE HAVE THE FOLLOWING TYPES OF

LEARNING:

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ONE BY THOUSANDS

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 FULL-TIME CLASSES IF NEAR OUR CLASSES IN KRUGERSDORP FOR

SELECTED N3 SUBJECTS PLEASE INQUIRE

ABOUT VIDEO MATERIAL

WE HAVE VIDEO MATERIAL FOR EXTRA UNDERSTANDING ON CERTAIN ENGINEERING SUBJECTS UNDER N3
CURRENTLY. WE WILL SOON BE HAVING N1 AND N2. THE CURRENT PRICE FOR A VIDEO IS R300
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