Metalwork - Exam Papers - HL - Paper - 2004

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

The diagram, Fig. 1a, shows some of the main parts of a basic four-stroke engine. Questions (b) to (e) relate to this diagram.

(a) Briefly describe, the contribution made to technology by one of the following people:
(i) Fr. Nicholas Callan, or
(ii) Michael Faraday, or
(iii) The Wright brothers.
(b) (i) Name Part ‘A’.
(ii) Explain the purpose of Part ‘A’. 
(c) (i) Name Part ‘B’.
(ii) Suggest a suitable material for Part ‘B’. 
(d) Briefly describe the function of Part ‘C’.
(e) Part ‘D’ shows a valve. What is the purpose of this valve?
(f) (i) Name one Thermosetting and one Thermoplastic material.
(ii) State one use for each chosen material.
(g) (i) Name and identify by number, any two of the four electronic components, shown in Fig. 1b.
(ii) Draw the symbol for one of the components identified.


Answer any five questions

The drawings in Fig. 1c show Part 11 and an assembly drawing of the 2004 Metalwork Higher Level Project, Model Helicopter.

(a) Name the tool used to mark-out and measure the angles on Part 11.
(b) Describe how the base, Part 1, made from acrylic, is bent to shape. 
(c) (i) Suggest a suitable material for the counterweight, Part 3. Give one reason for your choice.
(ii) Describe briefly, how the counterweight, Part 3, is attached to the rotating arm, Part 2. 
(d) Describe the function of the potentiometer, Part 18. 
(e) The slip rings, Parts 5, form part of the electronic circuit. Explain the purpose of these rings. 
(f) Sketch a suitable design for a landing pad for the helicopter and describe its main components.

(20 Marks)
A simple model of a design process is shown opposite.

(a) (i) List three sources of information you might use at the “Search for Information” stage.
(ii) List any three important points, which should be considered, at the “Materials Selection” stage.
(b) The diagram in Fig. 2 shows a metallic bracket and wooden sign to be fixed to a wall outside a Bed and Breakfast.
(i) Suggest a suitable metal for the bracket and give two reasons for your choice.
(ii) Using simple sketches and notes show how the bracket may be improved to give extra support to the sign.
(iii) Suggest a suitable finish for the bracket.
(20 Marks)
Fig. 3 shows four lathe-turning operations A, B, C and D. 

(a) (i) Name any three operations shown.
(ii) Explain the three operations named. 
(b) State two reasons why centre lathes are designed to run at different speeds (RPM).
(c) A 12mm diameter bar is to be turned on the lathe. The material has a surface cutting speed of 54m/min. Using the given formula, calculate the speed in RPM. (Take π as 3)
S X 1000
π X D
(d) Fig. 3 shows two tools X and Y, used on the lathe.
(i) Name both tools shown.
(ii) Explain the purpose of one tool shown.
(20 Marks)
(a) Name the type of furnace shown in Fig. 4. 
(b) List the materials in the charge. 
(c) (i) Name Parts ‘A’ and ‘B’.
(ii) Explain the function of both Parts.
(d) Explain what prevents Part ‘B’ from being melted by the heat?
(e) Describe briefly how this furnace is emptied.
(f) (i) Name the metal produced in this furnace.
(ii) Name one other furnace used to produce this metal.
(g) Redraw the table into your answer book. Complete the table, naming the alloys, and listing one important property of each.

Composition Alloy Property
Iron + Carbon    
Copper + Tin    
Copper + Zinc    
(20 Marks)
A bicycle and drive mechanism are shown in Fig. 5.

(a) (i) Name suitable materials for Parts ‘A’, ‘B’ and ‘C’.
(ii) List one reason for your choice of material in each case.
(b) (i) If the driving sprocket has 60 teeth, and the driven sprocket, attached to the rear axle, has 15 teeth, what is the gear ratio?
(ii) If the driving sprocket turns at 40 RPM, how fast does the rear wheel turn in RPM? 
(c) (i) Name the process used to join the links of the chain as shown.
(ii) State one other example of where this process is used.
(d) (i) The bicycle has pneumatic tyres. What are pneumatic tyres?
(ii) Name the Irishman who invented the pneumatic tyre.
(20 Marks)
An electric soldering iron and circuit to be soldered are shown in Fig. 6.

(a) (i) Name Part ‘A’ and state a material from which it is made.
(ii) Name the two metals used to make solder.
(iii) Describe three steps required to solder any two components shown.
  (iv) List three safety precautions to be observed while soldering.
(b) Discuss briefly the main differences between passive and active flux, as used in soldering.
(c) Explain the meaning of any two of the following terms associated with soldering:
(i) Conductivity;
(ii) Melting point;
(iii) States of matter;
(iv) Transformer.
(20 Marks)
(a) (i) Name the type of lathe shown in Fig. 7.
(ii) List three safety features included in this type of lathe.
(iii) Redraw the jog keys, Fig. 7a, into your answer book. Label the correct direction -X, +X, -Z and +Z on each key.
(iv) Explain any two of the following associated terms:
Canned cycle;
Test run.
(v) State two advantages of this type of lathe over a conventional lathe.

(b) Redraw the component, Fig. 7b, to be produced on the lathe. Illustrate using diagrams how it may be dimensioned using: 
(i) Absolute dimensioning;
(ii) Incremental dimensioning.