Engineering May 2011 Question and Mark Scheme Answers

Thermosetting polymers - One specific material - One significant property

Bakelite/Neoprene - Heat resistant, insulator, easily shaped

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Composites - One specific material - One significant property

Concret/MDF - Tough, easy to work

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New materials - One specific material - One significant property

Shape memory polymers/Piezo-electric crystals - Returns to shape after working, pressure produces current

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Elastomers - One specific material - One significant property

Rubber/Neoprene - Elasticity, shock absorbent

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Non-ferrous metals - One specific materials - One significant property

Aluminium/Zinc - Light, good strength/weight ratio, corrosion resistant

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Arc welding - One hazard involved in each process - One risk resulting from each hazard

Ultra violet/light radiation, hot metal - Eye damage, skin burns

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Sawing metal tube - One hazard involved in each process - One risk resulting from each hazard

Sharp edges, falling tube - cuts on hands, injured feet

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Injection moulding - One hazard involved in each process - One risk resulting from each hazard

Hot mould, fumes from release agent - Burns to hands, fume extractor

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Metal turning - One hazard involved in each process - One risk resulting from each hazard

Sharp edges, loose fragments(Swarf) - Cuts on hands, eye damage

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Outline the advantages and disadvantages of Galvanising

Durable, can be painted, seals cut edges, only suitable for low carbon steel, expensive, prevents corrosion/rusting

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Outline the advantages and disadvantages of Painting

Easy to apply, relatively cheap, easy to clean, can be chipped or cracked, flammable process, comes in a variety of colours/aesthetic

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Outline the advantages and disadvantages of Plastic Coating

Corrosion resistance, decorative, non-stick, expensive, relatively high thickness

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Explain the preparation and process of galvanising the metal frame, including health and safety precautions

Work chemically cleaned, heated to a suitable temperature, fluxed, molten zinc, aluminium added for bright finish, work dipped, work cooled, precautions against heat/PPE, ventilation

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Where on the graph is the range over which specimens extend elastically

Elastic range - Initial straight section

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Where on the graph is the ultimate tensile strength

Ultimate tensile strength - max point (highest point on curve)

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Where on the graph is the yield point

Yield point - first peak (Y)

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A specimen tested has a uniform cross section: length 100mm, cross sectional area 30mm^2. 6000N increases the length by 0.3mm. State the formula and calculate the strain

strain = increase/original length = 0.3/100 = 0.003

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A specimen tested has a uniform cross section: length 100mm, cross sectional area 30mm^2. 6000N increases the length by 0.3mm. State the formula and calculate the stress

stress = Force/Area = 6000/30x10^-6 = 200 x 10^6Nm^-2

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Explain the difference in properties between thermosetting polymers and thermoplastic polymers

Thermosetting - Rigid, brittle, not softened by heating, cannot be reshaped - Thermoplastic - More flexible, soften when heated, can be reshaped

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Name TWO materials used in the design of a lamp

Copper, steel, aluminium, PVC

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Describe ONE property of TWO materials used in the design of a lamp

Copper - Good conductor, flexible, malleable - Steel - High tensile strength, tough - Aluminium - Good conductor, cheap, ductile - PVC - Good insulator, flexible, cheap

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Describe using notes and sketches, how a hardness test is carried out

Brinell test - Steel/tungsten carbide ball indenter, downward load, test specimen, indentation

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When two materials are tested using the Brinell test, explain how one is shown to be harder than the other

Smaller diameter, of indentation of harder, material

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The support feet of the frame are manufactured from acrylonitrile-butadiene-styrene (ABS) using the injection moulding process. Explain why this process is suitable for the manufacture of the feet

Any shape can be obtained, complex shapes are possible, large numbers possible/quickly, economies of scale

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Two materials that can be used for the frame of the seatbox are aluminium alloy and low carbon steel. Discuss the advantages and disadvantages of using aluminium alloy and low carbon steel for the frame of the seatbox

Aluminium alloy - lightweight, corrosion resistant, expensive, lower tensile strength - low carbon steel - inexpensive, higher tensile strength than aluminium, heavy, dense, corrodes/rusts if not protected

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Engineering May 2011 Question and Mark Scheme Answers

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