Metalwork - Exam Papers - OL - Paper - 1995

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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) The holding device is a : Hand Vice  
Bench Vice  
Leg Vice  
Machine Vice  
(b) The tool is a(n) : Gas Pliers  
Adjustable Wrench  
Combination Pliers  
Vice Grips  
(c) The fastener is a : Grub Screw  
Self Tapping Screw  
Lock Nut  
Stud  
(d) This technique is called : Hardening  
Sweating  
Soldering  
Enamelling  
(e) The tool is a : Tap Wrench  
Split Die  
Die Stocks  
Ring Spanner  
(f) This technique is called : Parallel Turning  
Taper Turning  
Knurling  
Facing  
(g) The part 'X' is called the : Frame  
Ratchet  
Thimble  
Spindle  
(h) This technique is called : Riveting  
Planishing  
Upsetting  
Bending  
(i) This tool is called a(n) : Outside Callipers  
Spring Dividers  
Odd Leg Callipers  
Inside Callipers  
(j) Hacksaw blades are made from : High Speed Steel  
Mild Steel  
Cast Iron  
Stainless Steel  
(k) The part 'X' is called the : Frame  
Bevel  
Blade  
Stock  
(l) This tool is used for : Drilling  
Counterboring  
Reaming  
Countersinking  

SECTION B - 20 MARKS

ANSWER ALL QUESTIONS FROM THIS SECTION

(m)
(i) Complete the chart :
Cast Iron is used to make : Trains
Steel tube is used to make :  
Steel sheet is used to make :  
Aluminium sheet is used to make :  
Fibreglass is used to make :  
(ii) Can steel be galvanised ?
Yes  
No  
(n)
Using the labels briefly explain how the bicycle dynamo works :
 
 
 
 
(o)
(i) This mechanism is a :
(ii) This mechanism is a :
Disc Brake  
Drum Brake  
Stirrup Brake  
Calliper Brake  
Scissors Jack  
Ratchet  
Clutch  
Screw Jack  
(p)
(i) Part 'X' is called the :
(ii) Part 'Y' is called the :
Spark Plug  
Crank Shaft  
Piston  
Connecting Rod  
Alternator  
Fan Belt  
Cooling Fan  
Pulley  
(q)
(i) One turn of A = turns of B. (ii) Indicate with an arrow the pivot point of the brake lever.
A = 100 Teeth
B = 20 Teeth
2.
(20 Marks)
(a) (i) Complete the chart :
Material List a use made of any FIVE of the materials
Acrylic Shop Signs
Copper  
PVC  
Stainless Steel  
Nylon  
Bronze  
Lead  
Mahogany  
(ii) Brass is an alloy of :
Copper and Steel  
Copper & Tin  
Copper & Lead  
Copper & Zinc  
(b)
(i) Name this metal finishing process :
 
(ii) Explain briefly how copper is enamelled :
 
 
 
(c)
(i) Iron ore is smelted in a Blast Furnace.
Yes  
No  
(ii) Steel is produced by a Blast Furnace.
Yes  
No  
(iii) Steel is a ferrous metal.
Yes  
No  
(iv) Aluminium is a ferrous metal.
Yes  
No  
(v) Hardness is the ability of a metal to resist wear.
Yes  
No  
(vi) Lathe beds are made from cast iron.
Yes  
No  
3.
(20 Marks)
(a)
(i) Indicate with an arrow the direction of movement of the part (X) in each of the following :

(ii) Name a use for each of the following :

(a) Rack and Pinion.
(b) Crank/Slider mechanism.

(a)  
(b)  

(iii) Rotary motion is changed to reciprocating motion using a :

Bell Crank  
Bevel Gear  
Cam  
Ratchet  
(b)
(i) This mechanism is a :
Rack and Pinion  
Worm and Wormwheel  
Pulley System  
Chain and Sprocket  
(ii) This mechanism is a :
Bearing  
Crank and Slider  
Clutch  
Linkage  
(c)
(i) Complete the chart by naming any three inventors.
Invention Inventor
1. Micrometer  
2. Pneumatic Tyre  
3. Steam Engine  
4. Mass Production  
5. Submarine  
4.
(20 Marks)
(a)
(i) Why is copper used to make soldering iron bits ?
 
 
(ii) Name the soldering irons :
1.  
2.  
(iii) Surfaces to be soldered must be coated with :
Spelter  
Flux  
Tin  
Lead  
(b)
(i) Name these two forging techniques.
1.  
2.  
(ii) From what metal is an anvil made ?
 
(c)
(i) This technique is called :
 
(ii) List two safety operations to be observed when operating the forge.
1.  
2.  
5.
(20 Marks)
(a)
(i) Select the correct symbols from the chart and complete the circuit diagram for the Christmas tree star.
Circuit Layout Draw the circuit in this box Symbols
                   
                   
                   
                   
                   
                   
                   
                   
(ii) This electronic component is a :
Solenoid  
Bulb  
Light Emitting Diode  
Resistor  
(b)
Using the labels, briefly explain how the circuit works.
 
 
 
 
 
 
(c)
(i) State one use for a computer in the Metalwork room..
 
 
 
(ii) Is the computer an electronic device ?
Yes  
No  
6.
(20 Marks)
(i) The design shows a wind vane. List three workshop processes involved in making part (a).
1.  
2.  
3.  
(ii) State the design fault in art (c).
 
 
 
(iii) List three lathe processes involved in making part (b).
1.  
2.  
3.  
(iv) What process should be used to form part (c) ?
 
(v) Draw freehand, an elevation and an end view of part (b) in the squared section below.
USE A
PENCIL
ONLY