Metalwork - Exam Papers - HL - Paper - 1996

100 Marks


1. Answer Question 1, Sections A and B and three other questions.
2. All answers must be written in ink on the answer book supplied. Diagrams should be drawn in pencil.
3. Squared paper is supplied for diagrams as required.
4. Please label and number carefully each question attempted.

(40 Marks)


Answer any five questions

(a) Describe briefly, the contribution made to technology by one of the following :
Harry Ferguson;
Michael Faraday;
Thomas Edison.

(b) An illustration of a two-stroke engine is shown.
Name and identity two of the three parts A, D, and E.
State the purpose of these parts.

(c) State the function of part B.

(d) What causes part D to move downwards during the operation of this engine ?

(e) Give a use for this engine in everyday life.

(f) Name one ore mined in Ireland and state the location of this mine.

(g) Name a material suitable for the manufacture of bracelets and ear rings ?
State one property of this material.

(h) Examine the electronic circuit shown. Name and identify two of the components A, B and C.
Explain the meaning of 2k2 (Component D) ?


Answer any five questions

Figure 1 shows a windmill which generates electricity when the rotor is turned by the wind. The generator unit can rotate on its tower. Figure 2 shows the slip ring assembly (similar to the Metalwork Examination Project) for this unit.

(a) What is the purpose of the tail vane shown in Figure 1.

Draw a cross-sectional sketch of one of the slip rings and describe how a slip ring is made.

(c) Show with the aid of a sketch how the wires are connected between the slip rings and terminal box B.

(d) What is the function of parts A ?

(e) Draw a cross-section through either part C and name the materials and properties of the materials in this part.

(f) By means of a sketch show how the output wires (part C) are attached to the terminal ends of parts A.

(g) Define two of the following:

  1. Conductivity,
  2. Ductility,
  3. Metal Fatigue.
(20 Marks)
WARNING : Don't forget to return this section with your answer book (if question 2 is attempted) or otherwise marks will be lost.

(a) List four stages in the design process.

(b) You are required to design a steel basketball ring which will he mounted onto a 20 mm thick plywood board. Your design should include :
  1. A means of fixing the ring to the board.
  2. A method of preventing the ring from bending down when in use.
Rough sketches to illustrate your design ideas should be drawn in your answerbook Select a final design solution and make a working drawing of it (elevation and end view) on the squared paper below.

(c) Name two methods of treating the basketball ring against corrosion.

(d) If the ring diameter is 450mm estimate the length of material required to make the ring (Take π as 3).

(20 Marks)

(a) In soldering, explain the meaning of :

  1. Active flux and
  2. Passive flux ?

(b) Describe three important steps in the soft soldering of component A into the location tags.

(c) Explain two of the following terms : Pitch, thread angle, core diameter, tapping size hole.

(d) State two advantages the use of adhesives over the soldering process.

(e) Explain the meaning of two of the following :

  1. Toughness,
  2. Tempering,
  3. Density,
  4. Hardening.
(20 Marks)

(a) Identify one of the furnaces shown and state :

  1. Which metal is produced in the furnace you identified ?
  2. What materials make up the charge for this furnace ?
  3. What is the source of heat for this furnace ?

Elements used to make four alloys are listed in the table at A. B, C and D.


  1. Name three of these alloys and state an important property of each.
  2. Why do alloys play an important role in engineering ?


Tin + Lead


Copper + Zinc


Iron + Carbon


Copper + Tin

(20 Marks)

A pedestal grinding machine, of the type commonly used to sharpen cutting tools, is represented in the cutaway illustration shown :


  1. Identify, and state the function of two of the parts A, C and D.
  2. Describe, in detail, how the two grinding wheels are driven.


  1. If the diameter of B is made smaller, what effect will this have on the speed of rotation of the grinding wheels ?
  2. Make a sketch of parts A, B and C and show the direction of rotation of parts A and B.

(c) Explain the purpose of the two supports H and J.

(d) The plate E attached to part D carries the following specifications:

  1. 220V
  2. AC
  3. 1.5 kW

Explain the meaning of each of them.

(e) State two safety rules which must be observed when using the above machine.

(20 Marks)
The diagram shows a method of designing a simple bracelet.
(i) Design an alternative decorative bracelet to suit your own wrist, using the same method of designing.

(ii) On the drawing indicate a decorative finish for your bracelet.

(iii) Give a brief description of how to polish the bracelet.

(iv) With the aid of a sketch show how you would bend the bracelet to the shape of your wrist.

(v) Name and identify the two decorative processes shown opposite.

(vi) Name a suitable material for the bracelet.
(20 Marks)

An illustration of a CNC lathe used in CAM is shown.


  1. Explain the terms CNC and CAM.
  2. Identity and explain the purpose of parts C and E.
  3. Name the safety device omitted from the drawing of the lathe. Can the lathe work without this device ?
  4. Describe the purpose of the drawing B.
  5. At D, an enlarged view of part of the control panel is shown. Copy the view D into your answerbook and mark in the codes for the four arrows.

(b) A CNC programme consists of a number of lines called blocks. Each block contains the block number and the information needed to perform a certain operation. Pick four of the heading letters listed, and state the programme information noted under these letters.


Explain what is meant by two of the following :

  1. Test run,
  2. Tool offsets,
  3. Canned cycle.