Metalwork - Exam Papers - HL - Paper - 1997

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 in two sentences, the contribution made to technology by one of the following people :
Rudolf Diesel,
Guglielrno Marconi,
John Dunlop.

(b) The diagram shows parts of a four-stroke spark ignition engine.

  1. What type of fuel is used in this engine?
  2. Name another type of engine.

(c) Identify and name two of the parts A, B and C State the purpose of one of the parts you identified.

(d) With the aid of a sketch, explain the function of part D.

(e) What is the difference between a thermoplastic material and a thermosetting material? Give one example of each.

(f) Name one use of Cast Iron and give one reason why it is suitable for the use you mention.

Define two of the following: Malleability, Elasticity, Hardness.

(h) Four electronic components, 1, 2, 3 and 4, are shown. Four symbols are also shown. Identify and name two of the components. Match your two chosen components with the appropriate symbols.


Answer any five questions

The diagrams show an instrument for measuring electrical current.

(a) Explain what makes Part N move when current is fed through terminals T1 and T2.

(b) The wire at A is insulated. State :

  1. the material used for the wire and name one property that makes the wire suitable for this project.
  2. the meaning of insulation in this case.

(c) Describe in detail, how Part 2 is bent at right angles.

(d) Explain how the wire is wrapped onto the Pipe A.

(e) Explain the purpose of Parts 9.

(f) Make a freehand sketch of Part N showing how the pointer is attached to the balance weight.

(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) Study the dimensions and shape of the toothbrush and mouth-wash glass shown.
You are required to design a wall-mounted holder, to hold four such brushes and one glass. The holder should be formed from a single piece of material, and should include:

  1. Provision for, and details of how the completed holder may be fixed to a bathroom wall.
  2. A means of holding the glass and brushes in a stable position.

(b) Name a suitable material for the project.

Rough sketches to show your design ideas should he drawn in your answer hook. Select a final design solution, and make a pictorial (isometric) drawing of your final design on the special grid paper. Insert four leading dimensions.


  1. Describe four steps in the making of the holder.
  2. Give details of the tools and equipment used in its production.
(20 Marks)


  1. Name and identify three of the turning operations shown in the diagrams.
  1. A formula for finding speeds for turning or drilling is given as: N = (S x 1000) / (π x d)
  2. Use the formula above to calculate the lathe speed (N) required to turn a 25 mm diameter bar of mild steel (d) which has a cutting speed of 30 m/min (S). (Take π as 3 for the calculation).

(b) Describe, with the aid of sketches, how:

  1. Parallel shank drills and
  2. Morse taper shank drills are held in a lathe tailstock.

(c) Explain any two of the terms: Rake, clearance, depth of cut and feed.

(20 Marks)


  1. Identify the furnace shown.
  2. Name the two major parts of the charge. Which part of the charge goes into the furnace first, and why ?
  3. Name two important steps in the production process.
  4. Explain the purpose of Part A. How is this part kept cool during the process ?
  5. State one major advantage which this type of furnace has over the Electric Arc Furnace.

(b) Study the two tables, table A - Alloys, and table B - Compositions, shown below. In your answer-book, list three of the alloys from table A, and, in each case, match the alloy to the correct composition from table B.

Table A
Cast Steel
Soft Solder
Stainless Steel
Table B
Iron + Carbon + Nickel + Chromium
Copper + Zinc
Iron + 0.8% Carbon
62% Tin + 38% Lead
(20 Marks)

An illustration of an outboard motor for a small boat is shown.


  1. Explain how the removable plastic cover is formed.
  2. The body of the unit is made from an alloy. What particular property should the alloy have for this use ?

(b) An enlarged view of one of the mounting brackets is given. Describe, step by step, how the M10 screw thread is produced at C.

(c) Make a freehand sketch (on squared paper) of this bracket showing four dimensions that are necessary for it to be manufactured.

(d) Power from the engine is brought to the propeller via gears of the type shown.

  1. Name this type of gearing and state its function.
  2. With the aid of a sketch, explain how the propeller shaft could be made to turn faster than the engine shaft.

(e) How does the use of engines affect the environment?

(20 Marks)

Basic shapes for a pendant and a hair clasp are shown in the drawings.

(a) You are required to produce on paper, a decorative design for either the pendant or the hair clasp. Your design should be full size.

(b) Copper, 1 mm thick, is to be used to produce the finished article.

  1. Describe how copper can be annealed, and state why this may be necessary.
  2. List three properties of copper.

(c) Describe how one of the processes listed below is done.


Your description should include a list of tools and equipment necessary.

(d) List two safety precautions to be taken during the process you describe at (c). Why are these precautions necessary ?

(e) Name one famous piece of Irish metalwork, and state where it is kept.

(20 Marks)

Name the machine shown in the diagram.

(b) Identify and name three of the parts A, B, C, D. State the purpose of two of the three.

(c) Describe the sequence for the production of the profile shown. Use a number of simple sketches illustrate your answer.

(d) Explain what is meant by any three of the following: CD ROM. Hard Drive. RAM. DOS. Floppy Disk.

(e) Write down the 0-25 mm micrometer reading shown in the diagram.