Website: www.previouspapers.co.

za
Email: info@ previouspapers.co.za
CELL: 073 770 3028

PAST EXAM PAPER &

MEMO N1
ABOUT THE QUESTION PAPERS AND ONLINE INSTANT ACCESS:
THANK YOU FOR DOWNLOADING THE PAST EXAM PAPER AND ITS MEMO, WE HOPE IT WILL BE OF HELP TO
YOU. SHOULD YOU NEED MORE QUESTION PAPERS AND THEIR MEMOS PLEASE SEND US AN EMAIL TO
INFO@ PREVIOUSPAPERS.CO.ZA AND WE WILL SEND YOU A FULL DOWNLOAD VERSION OF THESE
THOUGH A FULL DOWNLOAD COMES AT A COST.

ALTERNATIVELY YOU CAN PURCHASE THEM ONLINE FROM OUR WEBSITE WWW.PREVIOUSPAPERS.CO.ZA
TO AVOID DELAYS AND YOU FOLLOW ALL THE NEEDED STEPS TO GET INSTANT DOWNLOAD. WITH ONLINE
PAYMENT YOU CAN GET INSTANT DOWNLOADS OF YOUR PURCHASE.

WE SELL PREVIOUS PAPERS AND MEMOS FOR THE SUBJECTS MENTIONED AND THE PAPERS ARE
BETWEEN 2014-2019. THE PAPERS ARE IN PDF FORM AND EACH PDF HAS A MINIMUM OF SEVEN DIFFERENT
PAPERS. THE YEARS FOR THE PAPERS YOU ARE PURCHASING ARE ALSO INCLUDED ON THE WEBSITE.

PRICE OF THE PAPERS AT A BIG DISCOUNT

Previous papers are very important in ensuring you pass your final exams. The actual value of the
papers we are making you access is way more than R1 000 and we are making these very cheap
as we have you in mind. For a small amount you can have these papers.

THE COST PER SUBJECT IS R300.

Website: www.previouspapers.co.za Email: info@previouspapers.co.za

 T1080(E)(M30)T
APRIL EXAMINATION

NATIONAL CERTIFICATE

METAL WORKERS' THEORY N1

(11022061)

30 March 2016 (X-Paper)

9:00–12:00

REQUIREMENTS: Drawing instruments

Calculators may be used.

This question paper consists of 6 pages and 1 addendum.

Copyright reserved Please turn over

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

DEPARTMENT OF HIGHER EDUCATION AND TRAINING

REPUBLIC OF SOUTH AFRICA
NATIONAL CERTIFICATE
METAL WORKER'S THEORY N1
TIME: 3 HOURS
MARKS: 100

INSTRUCTIONS AND INFORMATION

1. Answer ALL the questions.

2. Read ALL the questions carefully.

3. Number the answers according to the numbering system used in this question
paper.

4. Keep ALL the subsections of questions together.

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

8. Write neatly and legibly.

Copyright reserved Please turn over

(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]

Copyright reserved Please turn over

(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]

Copyright reserved Please turn over

(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)

Copyright reserved Please turn over

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

NATIONAL CERTIFICATE

APRIL EXAMINATION

METAL WORKERS' THEORY N1

30 MARCH 2016

This marking guideline consists of 7 pages.

Copyright reserved Please turn over

MARKING GUIDELINE -2- T1080(E)(M30)T
METAL WORKERS' THEORY N1

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]

Copyright reserved Please turn over

MARKING GUIDELINE -3- T1080(E)(M30)T
METAL WORKERS' THEORY N1

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)

3.4 See the sketch (4)

[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]

Copyright reserved Please turn over

MARKING GUIDELINE -4- T1080(E)(M30)T
METAL WORKERS' THEORY N1

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)
Copyright reserved Please turn over
MARKING GUIDELINE -5- T1080(E)(M30)T
METAL WORKERS' THEORY N1

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]

Copyright reserved Please turn over

MARKING GUIDELINE -6- T1080(E)(M30)T
METAL WORKERS' THEORY N1

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

Copyright reserved Please turn over

MARKING GUIDELINE -7- T1080(E)(M30)T
METAL WORKERS' THEORY N1

ADDENDUM

3.4

(4)

FIGURE 1

Copyright reserved
 Website: www.previouspapers.co.za
Email: info@ previouspapers.co.za
CELL: 073 770 3028

THANK YOU FOR

DOWNLOADING
PAST EXAM PAPER &
MEMO FOR N1
IF YOU NEED MORE PAPERS WE SELL THEM FOR R300

VISIT OUR WEBSITE AT WWW.PREVIOUSPAPERS.CO.ZA

OR SEND US AN EMAIL AT INFO@PREVIOUSPAPERS.CO.ZA AND

WE WILL GLADLY HELP YOU.

Website: www.previouspapers.co.za Email: info@previouspapers.co.za