Metalwork - Exam Papers - OL - Paper - 2009

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) A die is used for: Tapping  
Reaming  
Screwing  
Riveting  
(b) This instrument is a: Micrometer  
Vernier Calipers  
Bevel Gauge  
Feeler Gauge  
(c) A centre drill is used with a: Pillar Drilling Machine  
Lathe  
Hand Drill  
Tap Wrench  
(d) This fastener is a: Wing Nut  
Spring Washer  
Split Pin  
Lock Nut  
(e) Part ‘X’ is called the: Point  
Face  
Edge  
Tang  
(f) A gas torch is used when: Threading  
Soldering  
Welding  
Riveting  
(g) This thread form is a(n): Square Thread  
Butress Thread  
Acme Thread  
ISO Metric Thread  
(h) This technique is called: Drawing Down  
Hardening  
Forming an Eye  
Upsetting  
(i) Hammers are classified by: Length of Shaft  
Diameter of Head  
Total Weight  
Weight of Head  
(j) This holding device is a: Leg Vice  
Bench Vice  
Hand Vice  
Machine Vice  
(k) This drawing shows a: Counterbored Hole  
Contersunk Hole  
Pilot Hole  
Blind Hole  
(l) This technique is called: Taper Turning  
Parallel Turning  
Facing  
Knurling  

SECTION B - 20 MARKS

ANSWER ALL QUESTIONS FROM THIS SECTION

(m)
Complete the chart by listing a different metal for the body of each item.
Item Metal
Stove  
Saucepan  
Padlock  
Hot Water Cylinder  
(n)
(i) Why should we recycle plastics?
 
 
 
(ii) Name two plastic items that can be recycled.
1.
2.
(o)
(i) Bathroom taps are coated with: (ii) Name the metal used to galvanise gates.
Tin  
Steel  
Lead  
Chrome  
 
(p)
(i) Placing a design into metal with a
sharp tool is called:		 (ii) Why is lacquering applied to copper jewellery?
Enamelling  
Engraving  
Etching  
Repoussé  
 
 
 
 
(q)
(i) The case is a(n): (ii) The pin is a(n):
Insulator  
Conductor  
Semi-conductor  
Insulator  
Conductor  
Semi-conductor  
2.
(20 Marks)
(a) (i) Complete the chart (The first row has been completed for you, as an example):
Component Metals Alloy Formed List a use for each alloy
Aluminium and Copper Duralumin Aircraft manufacture
Lead and Tin    
Copper and Tin    
Copper and Zinc    
(ii) What happens to a thermoplastic material when heated?
 
(iii) Name one thermoplastic material.
 
(b) Describe how steel is produced using the basic oxygen process.
 
 
 
 
 
 
 
 
 
 
(c) Complete the chart:

Can brittle materials bend easily?

 Yes  
No  

Can steel be hardened and tempered?

 Yes  
No  

Are non-ferrous metals magnetic?

 Yes  
No  

Is the malleability of most metals increased by heating?

 Yes  
No  

Is toughness the ability of a material to withstand blows?

 Yes  
No  

Is hardness the ability of a material to resist wear?

 Yes  
No  
3.
(20 Marks)
(a) (i) Match each of the numbers below to the correct mechanism part listed on the table.
Mechanism No.
Bearing  
Gear Train  
Leadscrew  
Cam  
Worm and Wormwheel  
Bevel Gears  
(ii) Name a machine that uses a rack and pinion mechanism.
 
(b) (i) Indicate with an arrow the direction of gear ‘X’ in each of the following:
(ii) If gear ‘A’ rotates at 10 RPM
how fast will gear ‘B’ rotate?
(A = 10 Teeth, B = 20 Teeth.)
100 RPM  
10 RPM  
50 RPM  
5 RPM  
(iii) Is gear ‘A’ known as a pinion?
Yes  
No  
(c) Complete the chart by listing devices that use the following mechanisms.
The first row has been completed for you, as an example.
Mechanism Device
Lever Nutcracker
Ratchet and Pawl  
Pulleys  
Linkages  
Spur Gears  
Rack & Pinion  
Crankshaft  
4.
(20 Marks)
Details of the fin-wheel support used in the manufacture of a model biplane are shown.
(i) List the tools that you would use when marking out the fin-wheel support.
 
 
 
 
(ii) What is the overall length and width of the fin-wheel support?
Length:
Width:
(iii) Describe how you would cut out and shape the fin-wheel support.
 
 
 
 
(iv) Describe how you would safely drill the holes in the fin-wheel support.
 
 
 
 
(v) Describe how you would make the front wheel.
 
 
 
 
 
 
(vi) What safety precautions should you take when operating a lathe?
 
 
 
 
5.
(20 Marks)
(a) (i) Using the circuit diagram as a reference, draw the connecting
wires between the components in the box below.
(ii) Name the components shown above.
A  
B  
C  
(iii) State a use for component ‘C’.
 
 
(b)
(i) A bulb converts electrical energy into:
Chemical Energy  
Mechanical Energy  
Light Energy  
(iv) This component is a(n):
Integrated Circuit  
Buzzer  
Relay  
(ii) This device is a:
Slide Switch  
Toggle Switch  
Push Switch  
(v) A computer monitor is a(n):
Output Device  
Input Device  
Process Device  
(iii) Electric current is measured in:
Ohms  
Volts  
Amps  
(vi) This component is a(n):
LDR  
Fuse  
Transistor  
(c)
(i) From the history of transport name one famous inventor:
 
(ii) What did this person invent?
 
 
(iii) How has this person’s invention changed the way we live?
 
 
6.
(20 Marks)
(i) A design for a plate stand made from clear acrylic is shown. Why is acrylic
a suitable material for this project?
 
 
 
 
 
(ii) Describe how you could get the best finish possible on the edges of the plate stand.
 
 
 
 
 
(iii) Using the chart below describe the cutting and shaping processes to be used
to make the plate stand. List the tools used at each stage.
Cutting: Tools used:
   
   
   
   
Shaping: Tools used:
   
   
   
   
(iv) Draw a development of the plate stand in this box.