Metalwork - Exam Papers - HL - Paper - 2007

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. 1, 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) Heinrick Focke, or
(ii) Henry Ford, or
(iii) Nicholas Otto.
(b) (i) Name part ‘B’.
(ii) Name part ‘B’.
(c) Explain the function of the piston rings.
(d) Describe one of the following engine strokes:
(i) Induction;
(ii) Ignition.
(e) (i) Outline one environmental effect of engines.
(ii) Suggest how this effect could be reduced.
(f) (i) Name a suitable plastic, which could be used to make the guttering shown.
(ii) Is the plastic named a Thermoset or a Thermoplastic?
(g) (i) Identify components ‘C’ and ‘D’ in the electronic circuit shown.
(ii) The circuit is connected to a cell marked 9V. Explain the meaning of 9V.


Answer any five questions

The drawings show the Valve Chest, Flywheel, Electric Circuit and an assembly drawing of the 2007 Metalwork Higher Level Project, Model Steam Engine.

(a) List four safety precautions to be observed while making the model.
(b) Describe any two processes used to manufacture the valve chest.
(c) List three lathe processes used to make the flywheel.
(d) Describe briefly the operation of the electric circuit.
(e) Design, using a diagram, a suitable support for the flywheel.
(f) Suggest two suitable applications for a steam engine.

(20 Marks)
A simple model of a design process is shown opposite.
(a) (i) List three elements which should be included in the ‘production drawings’.
(ii) Discuss two factors which could be considered at the ‘test’ stage.
(b) (i) Draw an elevation of the trailer looking in the direction of arrow ‘A’.
(ii) Describe how the trailer may be attached to a car for towing.
(iii) Design, using suitable diagrams, a ramp that could be attached to the trailer allowing a ride-on lawnmower to be loaded.
(iv) Suggest a suitable metal and a suitable finish for your ramp.

(20 Marks)
(a) (i) Name parts ‘A’, ‘B’, ‘C’ and ‘D’ of the pillar drilling machine shown.
(ii) Describe the mechanism used to raise and lower part ‘C’.
(iii) List two safety precautions to be observed when working on this drill.
(b) An 8 mm hole is to be drilled in a material which has a surface cutting speed of 36 m/min. Using the given formula calculate the speed in RPM. (Take π as 3)
S X 1000
π X D
(c) Select any two of the following and explain the difference between the terms:
(i) Countersinking and Counterboring;
(ii) Clearance hole and Tapping hole;
(iii) Taper tap and Plug tap.
(20 Marks)
(a) Name the type of furnace shown.
(b) List the materials in the charge.
(c) Describe briefly how the charge is melted.
(d) Explain the function of parts ‘A’ and ‘B’ shown.
(e) (i) Name the metal produced by this furnace.
(ii) List two properties of this metal. 
(f) (i) List the two metals used to make each of the following alloys:
(ii) Suggest one application for each of the alloys listed.
(20 Marks)
(a) (i) Name one suitable material for each tractor part shown.
(ii) Suggest a suitable method to lubricate the tractor engine.
(iii) Name a suitable fuel used to power the tractor engine.
(iv) The tractor has pneumatic tyres. Explain the meaning of ‘pneumatic’.
(v) Describe how power is transmitted from the back of the tractor to attachments, such as mowers and spreaders.
(b) Gear wheels ‘A’, ‘B’, and ‘C’ are parts of the transmission system.
(i) If wheel ‘A’ is turning clockwise, in what direction will wheel ‘C’ turn?
(ii) If the driving wheel ‘A’ has 20 teeth and driven wheel ‘C’ has 40 teeth, what is the gear ratio?
(iii) If wheel ‘A’ is turning at 500 RPM, what is the speed of wheel ‘C’?
(20 Marks)
The blade of a screwdriver and material for a bracelet are shown.
(a) (i) Name a suitable metal which could be used to make the blade.
(ii) Briefly describe the tempering process applied to the blade following hardening.
(iii) List two safety precautions to be observed when heating metals. 
(b) Explain any two of the following terms:
(i) Annealing,
(ii) Brittleness,
(iii) Conductivity,
(iv) Ductility.
(c) (i) Describe, using a diagram, how the bracelet may be bent to shape.
(ii) Briefly describe any two of the following decorative processes which could be used to finish the bracelet:
(20 Marks)
(a) (i) Four computer devices are shown. Classify each as an input or output device.
(ii) Explain any two of the following computer terms:
(iii) Describe briefly how to protect a personal computer (PC) from:
Electrical surge
(iv) Name the three computer file storage devices shown.
(b) (i) Explain the meaning of the term CNC.
(ii) List one similarity and one difference between a CNC lathe and a conventional lathe.
(iii) What is CAD/CAM?
(iv) List two advantages of a CAD/CAM system.