Metalwork - Exam Papers - OL - Paper - 2001

100 Marks

INSTRUCTIONS

1. Answer question 1, sections A and B, and any three other questions.
2. Write your answers in the space provided or tick the appropriate box.
3. Hand up this paper at the end of the examination.

1.
(40 Marks)

SECTION A - 20 MARKS

ANSWER ANY TEN QUESTIONS FROM THIS SECTION

(a) After hardening, cold chisels should be: Annealed  
Enamelled  
Tempered  
Normalised  
(b) This fastener is a: Grub Screw  
Cheese Head Screw  
Round Head Screw  
Countersunk Screw  
(c) This cutting tool is a: Die Nut  
Split Die  
Hand Reamer  
Centre Drill  
(d) This tool is a: Round File  
Half-Round File  
Square File  
Flat File  
(e) This sign warns of a(n): Toxic Hazard  
Fire Hazard  
Radiation Hazard  
Electrical Hazard  
(f) This instrument is a(n): Vernier Calipers  
Inside Calipers  
Outside Calipers  
Odd-leg Calipers  
(g) The point angle of a standard twist drill is: 118°  
150°  
210°  
60°  
(h) This lathe technique is called: Parting Off  
Undercutting  
Knurling  
Facing  
(i) This tool is a(n): Adjustable Spanner  
Box Spanner  
Ring Spanner  
Open Spanner  
(j) This tap is used to cut: Acme Threads  
Square Threads  
ISO Metric Threads  
Buttress Threads  
(k) This tool is used with a: Brazing Hearth  
Power Saw  
Forge  
Drilling Machine  
(l) This forging technique is called: Drawing Down  
Forming an Eye  
Upsetting  
Punching  

SECTION B - 20 MARKS

ANSWER ALL QUESTIONS FROM THIS SECTION

(m)
(i) Complete this chart by naming a non-ferrous metal suitable for each part:
Part Non-Ferrous Metal
1. Window Frames  
2. Key  
3. Guttering  
4. Roof Flashing  
(ii) Name a plastic material suitable to make both the window frame and the guttering.
 
(n)
(i) The earth wire is colour coded: (ii) Household electricity uses:
Red  
Brown  
GreenlYellow  
Blue  
100VAC  
160V AC  
220V AC  
540V AC  
(o)
(i) Galvanised iron is mild steel coated with: (ii) Which one of the following is an alloy?
Zinc  
Tin  
Copper  
Silver  
Iron  
Copper  
Zinc  
Solder  
(p)
(i) Metal camping chairs are lightweight because they are made from: (ii) A lever pivots about a fixed point called a:
Solid Section  
Tubular Section  
Triangular Section  
Square Section  
Structure  
Fulcrum  
Linkage  
Caliper  
(q)
(i) Olympic medals are made from: (ii) Which of the following metals is the best conductor of heat?
Silver, Gold, Pewter  
Zinc, Gold, Silver  
Silver, Bronze, Gold  
Tin, Gold, Silver  
Mild Steel  
Cast Iron  
Copper  
High Carbon Steel  
2.
(20 Marks)
(a)
(i) Complete the chart:
Plastic Material Thermosetting or Thermoplastic List a use for each plastic
Polyurethanes Thermosetting Flexible foam for upholstery
Polythene    
Acrylic    
Nylon    
(ii) The ability of a metal to withstand wear is called:
Elasticity  
Hardness  
Brittleness  
Malleability  
(b)
Complete the chart:
(i) Is the melting of a glass powder onto copper called enamelling? Yes  
No  
(ii) Is hollowing a method used to form copper bowls? Yes  
No  
(iii) Does copper work harden? Yes  
No  
(iv) Is repousse the method used to produce raised designs in copper? Yes  
No  
(v) Does copper rust? Yes  
No  
(vi) Does engraving involve the use of acid? Yes  
No  
(c)
Complete the chart:
(i) Does this furnace produce Pig Iron? Yes  
No  
(ii) Does molten metal form part of the charge for this furnace? Yes  
No  
(iii) Is this a Basic Oxygen Furnace? Yes  
No  
(iv) Is hot air blown through the tuyeres of this furnace? Yes  
No  
(v) Can this furnace be tilted to pour the molten metal? Yes  
No  
(vi) Does molten metal fall to the bottom of this furnace? Yes  
No  
3.
(20 Marks)
(a)
(i) Indicate with an arrow the direction of movement of part 'X' in each of the following:
(ii) Name a machine that uses a rack and pinion mechanism.
 
(b)
Answer the following:
(i) Is gear 'B' turning anti-clockwise?
Yes  
No  
(iv) Is part 'X' called a cotter pin?
Yes  
No  
(ii) Is part 'X' called a rachet?
Yes  
No  
(v) Can gears be made from nylon?
Yes  
No  
(iii) Does gear 'B' turn faster than gear 'A'?
Yes  
No  
(vi) Are these gears known as bevel gears?
Yes  
No  
(c)
Name the mechanism part indicated by 'X' in each of the following :
Name : _________________
Name : _________________
Name : _________________
4.
(20 Marks)
Details of a Wind-Powered Pump are shown.
(i) List the steps involved in making the Shaft Support from a blank piece of metal.
 
 
 
 
(ii) What does 'Ø3.5x4' refer to in this drawing? (iii) What is the overall height of the Shaft Support?
 
 
 
 
 
(iv) What safety precautions should be taken when drilling sheet metal? (v) The Windvane is to be made from brass, copper or aluminium. What have these metals got in common?
 
 
 
 
 
 
 
 
(vi) Draw a development of the Shaft Support in the grid below
USE A
PENCIL
ONLY
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
       
5.
(20 Marks)
(a)
(i) Select the correct symbols from the chart and complete the electrical circuit diagram for this motor powered vehicle.
Symbols
Draw the circuit in this box
                   
                   
                   
                   
                   
                   
                   
                   
(ii) Does a battery supply A.C. current?
Yes  
No  
(iii) Does a motor convert electrical energy into mechanical energy?
Yes  
No  
(b)
(i) This electronic component is a(n):
Resistor  
Buzzer  
Integrated Circuit (lC)  
Transistor  
(ii) This symbol represents a(n):
Switch  
LDR  
LED  
Bulb  
(iii) Complete the chart:
Can the speed of an electric motor be changed? Yes  
No  
Does solder, used for electronics, contain flux. Yes  
No  
(c)
Complete the chart by matching the inventor to the invention. Inventors:
Rudolf Diesel, John P. Holland, James Watt, Nicholas Otto, John Dunlop, Alexander Graham Bell
Invention Inventor
1. Diesel Engine  
2. Submarine  
3. Four Stroke Engine  
4. Pneumatic Tyre  
5. Steam Engine  
6. Telephone  
6.
(20 Marks)
This drawing shows details of a mild steel wall bracket for a bird house.
(i) What is the total length of part 'A'?
 
(ii) How would you join part 'A' to part 'B'?
 
(iii) How would you prevent the wall bracket from rusting?
 
(iv) Give details on this drawing, (in the circled section), of how the wall bracket could be strenghtened.
(v) Does mild steel contain between 0.15% - 0.30% carbon?
Yes  
No  
(vi) Briefly describe how the hook at the end of part 'B' could be formed.
 
 
 
 
(vii) Draw full size, in the box below, a complete development of part 'A' showing all bend lines. (Width of part 'A' = 50mm) -,
USE A
PENCIL
ONLY