Metalwork - Exam Papers - HL - Paper - 2008

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) John B. Dunlop , or
(ii) John L. Baird , or
(iii) James Watt .
(b) (i) Identify each of the valves shown.
(ii) Name the engine stroke for which Valve A opens.
  (iii) Name the engine stroke for which Valve B opens.
(c) Describe the mechanisms used to open and close the valves.
(d) (i) Identify part 'D'.
(ii) State the purpose of part 'D'.
(e) (i) Name one other type of engine
(ii) Suggest a suitable application for the engine named.
(f) Define any two of the following material properties :
(i) Hardness;
(ii) Malleability;
  (iii) Toughness;
  (iv) Elasticity.
(g) (i) Identify any two of the electronic components shown.
(ii) Draw the electronic symbol for one of the components identified

Fig. 1


Answer any five questions

The drawings show the Rear Wheel Guard, Electronic Circuit and an assembly drawing of the 2008 Metalwork Higher Level Project, Model Quad Bike
(a) (i) Calculate the overall length of the
rear wheel guard.
(ii) Describe how the 48 mm × 40 mm
section marked ‘X’ on the rear wheel
guard is shaped.
(b) (i) Explain how to locate the centre of the
R25 arc when marking out the rear
wheel guard.
(ii) Describe how the rear wheel guard is
bent to shape.
(c) (i) Explain the term knurling as used to
make the rear wheels.
(ii) List any two other lathe processes
used to make the rear wheels.
(d) (i) Explain the function of the DPDT
switch used in the electronic circuit.
(ii) Outline the purpose of the resistor
used in the electronic circuit.
(e) Design, using a diagram, a suitable front
wheel support and steering mechanism for
the Quad Bike.
(f) Suggest any two suitable applications for a
Quad Bike.

Rear Wheel Guard

Electronic Circuit

Model Quad Bike
(20 Marks)
A simple model of a design process is
shown opposite.
(a) (i) Outline any three possible
sources used to “Search for
(ii) Describe any two ways in
which ideas could be
developed following the
“Research” stage.
A double-sided menu board to be
placed on the footpath outside a café
is shown.
(b) (i) Design a suitable metal stand
to hold the board.
(ii) Show, using a diagram, how
the board is securely attached
to the stand.
(iii) Suggest a suitable metal for the
(iv) Describe a suitable finish
which should be applied to the
chosen metal.

Menu Board
(20 Marks)
(a) (i) Name parts ‘A’ and ‘B’ of the lathe
(ii) Outline any two functions of the
(iii) State any two reasons why lathes are
designed to run at different speeds
(iv) List any two safety precautions to be
observed when working on the lathe.
(b) A 10 mm diameter bar is to be turned on the
lathe. The material has a surface cutting
speed of 78 m/min. Using the given formula
calculate the speed in RPM (Take π as 3).
(c) (i) Name each of the tools shown
(ii) Explain the purpose of one of the

Tool A

Tool B
(20 Marks)
(a) (i) Name the type of furnace shown.
(ii) With reference to bells ‘A’ and
B’, explain how the charge is put into
the furnace without heat loss.
(iii) Explain the purpose of the tuyere.
(iv) Outline the function of chutes ‘C’ and
(b) (i) Name any two non-ferrous metals.
(ii) Suggest one suitable application for
each metal named.
(c) (i)

List the elements used to make each
of the following alloys:

  • Bronze;
  • Stainless steel.
(ii) Identify the alloy used to
manufacture each of the objects


(20 Marks)
A fuel pump, pulley and belt drive mechanism
and a vee belt system are shown.
(a) (i) Name one suitable material for each
fuel pump part labeled.
(ii) State one reason for the selection of
each material.
(iii) Outline any two safety precautions to
be observed when using a fuel pump.
(iv) Describe any two environmental effects
caused by the use of petrol.
(b) (i) Identify any two other drive
(ii) Explain, using a diagram, how the
direction of rotation of the driven pulley
may be reversed.
(iii) Outline one advantage of a vee belt
pulley system.

Vee Belt System
(20 Marks)
(a) Compare the two soldering irons shown using
the following guidelines:
(i) Name of soldering iron;
(ii) Method of heating;
(iii) Material used in the bit;
(iv) Material used in the handle;
(v) One safety precaution to be observed
with each iron.
(b) Select any two of the following and explain
the difference:
(i) between a conductor and an insulator;
(ii) between a passive flux and an active
(iii) between soft solder and silver solder.
(c) (i) Name any two common thermoplastics.
(ii) Suggest one suitable application for
each plastic named.

Iron A

Iron B
(20 Marks)
(a) (i) Redraw the given table into your
answer book. Complete the table by
filling the missing input/output and
application boxes.

Explain any two of the following
computer terms:

  • Byte;
  • File;
  • VDU;
  • CD-ROM.
(iii) Name parts ‘A’ and ‘B’ of the CNC
lathe shown.
(iv) Identify any two safety features of
the CNC lathe.

For each of the following state the

  • between G codes and M codes;
  • between Absolute dimensioning and
    Incremental dimensioning.
Name Input / Output Application
Mouse Input  
Digital Camera   Images / pictures
Plotter Output  

CNC Lathe
(b) (i) Name each of the measuring
instruments shown.
(ii) Identify parts ‘C’ and ‘D’
(iii) What is the value of the reading shown
below opposite?

Instrument A

Instrument B