Engineering - Exam Papers - HL - Paper - 2006
300 Marks
Answer Question 1, Sections A and B and FOUR other questions.
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1.
(100 Marks)
Section A - 50 Marks
Give brief answers to any ten of the following :
| (a) | State the purpose of any one of the safety symbols shown. |
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| (b) | State two factors that affect corrosion rates in metals. |
| (c) | In oxy-acetylene welding what is meant by dissolved acetylene? |
| (d) | Identify the main process used to manufacture any two of the items shown: |
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| (e) | Outline two safety precautions to be observed when working with toxic materials. |
| (f) | Differentiate between a torsion force and a shear force. |
| (g) | What contribution did any one of the following make to technology? (i) Ivan Sikorsky, (ii) Theodore Maiman, (iii) Dugald Clerk. |
| (h) | Identify and outline the function of any one of the electronic components shown: |
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| (i) | List two essential advantages of using non-metals over metals. |
| (j) | Describe the flotation separation method used in ore dressing. |
| (k) | Explain the term copolymer. |
| (l) | Select any two of the
abbreviations shown and explain their meaning: (i) CPU (ii) ISP (iii) CD-RW (iv) E-MAIL. |
| (m) | Name and suggest a suitable application for the gauge shown. |
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Section B - 50 Marks
Answer all of the following :
| (n) | Outline three advantages of using pneumatic sequential control in industry. |
| (o) | With reference to the pneumatic
sequential control circuit shown: (i) Name the components C, D, E and F; (ii) Describe the function of any two components named. |
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| (p) | With reference to pneumatic
sequential control describe any two of
the following: (i) Cascade circuit, (ii) PLC, (iii) FRL. |
| (q) | (i) State two industrial
applications where pneumatic sequential control
is used. (ii) What are the benefits of using compressed air systems in industry? |
| (r) | Utilising the diagram shown below, describe the sequence of operations which will ensure that the component is drilled safely. |
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2.
(50 Marks)
| (a) | Answer any two of the following: | ||||||||||||||||||||||
| (i) | Compare the indenters used in Brinell and Vickers hardness tests; | ||||||||||||||||||||||
| (ii) | With reference to tensile testing, explain the elastic limit of a material; | ||||||||||||||||||||||
| (iii) | Identify two factors necessary to prevent early fatigue failure in a component. | ||||||||||||||||||||||
| (b) | The following data was obtained from a tensile test on a specimen of 10mm diameter and gauge length 60mm. | ||||||||||||||||||||||
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| Using the graph paper supplied, plot the load-extension diagram and determine: | |||||||||||||||||||||||
| (i) | The tensile strength; | ||||||||||||||||||||||
| (ii) | Young’s Modulus for the specimen. | ||||||||||||||||||||||
| (c) | (i) | State two reasons why non-destructive tests are necessary in industry. | |||||||||||||||||||||
| (ii) | Describe, with the aid of a diagram, a test suitable for the detection of internal flaws. | ||||||||||||||||||||||
3.
(50 Marks)
| (a) | Temperature zones, A, B, C and D, for a
range of heat-treatment processes for carbon
steel are shown below. Select any two zones and explain the heat-treatment process that they represent. |
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| (b) | For any two of the following, differentiate between the terms: | |
| (i) | Ferrite and martensite; | |
| (ii) | Upper critical temperature and lower critical temperature; | |
| (iii) | Stainless steel and high speed steel; | |
| (iv) | Eutectic and eutectoid point. | |
| (c) | With reference to the diagram shown below: | |
| (i) | Name the instrument; | |
| (ii) | State its function; | |
| (iii) | Outline the method of operation. | |
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4.
(50 Marks)
| (a) | Explain any two of the following: | |
| (i) | Solid solution alloy; | |
| (ii) | Dendritic growth; | |
| (iii) | Allotropy; | |
| (iv) | Cooling curve. | |
| (b) | Copy the given lead-tin diagram into your answer book and answer all of the following: | |
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| (i) | Identify the lines labelled A, B and C; | |
| (ii) | Explain what each line represents; | |
| (iii) | For the alloy with 30% tin determine, from the diagram, the composition of the phases at 250°C; | |
| (iv) | Indicate clearly on your diagram the eutectic point. | |
| (c) | Describe any two of the crystal defects shown below. | |
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5.
(50 Marks)
| (a) | Describe the welding process shown using the following guidelines: | ||
| (i) | Name; |  |
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| (ii) | Method of operation; | ||
| (iii) | Applications. | ||
| (b) | With reference to manual metal arc welding answer any three of the following: | ||
| (i) | State two functions of the electrode coating; | ||
| (ii) | Outline two important functions of the slag produced; | ||
| (iii) | Explain the operation of a bridge rectifier; | ||
| (iv) | Identify three potential safety hazards and suggest a suitable remedy for each. | ||
| (c) | Describe, with the aid of a suitable diagram, the main features of one of the following: | ||
| (i) | Resistance spot welding; | ||
| (ii) | Tungsten inert gas welding. | ||
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| (c) | (i) | Outline the benefits of using robots in car assembly. | |
| (ii) | In robotic control explain the meaning of the working envelope. | ||
6.
(50 Marks)
| (a) | Distinguish between thermoplastics and thermosetting plastics under each of the following guidelines: | |
| (i) | Chemical bonding; | |
| (ii) | Polymerisation process; | |
| (iii) | Internal structure; | |
| (iv) | Properties. | |
| (b) | State the function of any three of the following in relation to polymers: | |
| (i) | Filler; | |
| (ii) | Stabiliser; | |
| (iii) | Catalyst; | |
| (iv) | Foaming agent. | |
| (c) | Describe the process shown in the diagram below using the following guidelines: | |
| (i) | Name and describe the principle of operation; | |
| (ii) | Identify one component produced; | |
| (iii) | Name parts A, B, C and D. | |
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7.
(50 Marks)
| (a) | Answer any two of the following: | |
| (i) | Identify three machining processes used to produce a cylindrical surface; | |
| (ii) | Differentiate between the milling operations shown below; | |
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| (iii) | State three advantages of using the cutting tool shown below in a turning operation. | |
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| (b) | Distinguish clearly between any three of the following: | |
| (i) | Loading and glazing; | |
| (ii) | Feeler gauge and drill gauge; | |
| (iii) | Rake angle and clearance angle; | |
| (iv) | Gang milling and straddle milling. | |
| (c) | Identify two safety hazards associated with each of the following: | |
| (i) | Using cutting fluids; | |
| (ii) | Machining mild steel. | |
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| (c) | With reference to CNC machining answer any two of the following: | |
| (i) | Differentiate between incremental and absolute dimensioning; | |
| (ii) | Explain the operation of a stepper motor; | |
| (iii) | State one advantage of using a canned cycle when programming for machining. | |
8.
(50 Marks)
| (a) | Describe the operation and outline a suitable application for one of the mechanisms shown. | |
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| (b) | Answer any three of the following: | |
| (i) | Explain the function of a compound gear train; | |
| (ii) | State one advantage of using gears over pulleys; | |
| (iii) | Outline the function of an idler gear; | |
| (iv) | Outline the function of an idler gear; | |
| (v) | Describe two applications of a rack and pinion mechanism. | |
| (c) | Describe, with the aid of a diagram, the principle of operation of a power hacksaw. | |
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| (c) | With reference to the circuit shown below: | |
| (i) | Identify the electronic components A, B, C and D. | |
| (ii) | Explain the operation and suggest an application for the circuit. | |
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