Engineering May 2012 Questions and Markscheme answers

Metal - one specific material - one significant property

Aluminium/Copper - Low density, ductile, malleable, good conductivity

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Alloy - one specific material - one significant property

Stainless steel/Brass - Hard, corrosion resistanct

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Elastomer - one specific material - one significant property

Rubber/Neoprene - Insulator, elasticity, flexible

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Polymer - one specific material - one significant property

PVC/ABS - lightweight, insulator, flexibility

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Injection moulding - one hazard involved in each process - one precaution/control measyre for each process

Trapped limbs, fumes from release agent - Guards on machine, good ventilation

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Cyanoacrylates adhesive bonding - one hazard involved in each process - one precaution/control measure for each process

Gluing fingers together, contact with eye/skin, fumes, chemical burns - avoid skin contact, safety glasses

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Metal pressing - one hazard involved in each process - one precaution/control measure for each process

Sharp edges, moving parts, trapped limbs - guards on machine, wear gloves

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Oxy acetylene welding - one hazard involved in each process - one precaution/control measure for each process

Danger of burning from flame/sparking, glare, danger of work falling over - wear welding goggles, wear gloves, secure work, safety mask

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Connecting wire from the CD player to the 13A plug - Material - Explanation

Copper - Has the least resistivity, conducts effectively, ductile, enables it to be drawn in to a fine wire, high tensile strength

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The body of the 13A plug - Material - Explanation

Urea formaldehyde - high resistivity, good insulation properties, protects from electric shocks, low thermal conductivity, will not get too hot

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Electrical terminals - Material - Explanation

Brass - Good tensile strength, retains its shape, low resistivity, conducts effectively, will not corrode

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The casing of the player - Material - Explanation

High impact polystyrene - Low density, lightweight, can be produced in various colours for aesthetic reasons, easy to injection mould, can be mass produced, low electrical conductivity, low thermal conductivity

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Describe the process of Crimping

***** cable end, position sleeve of lug on cable end, set crimping tool (or press) to correct size, apply pressure

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Describe the process of Soft Soldering

***** cable end, tin cable end, apply flux, fit lug to cable end, apply heat, apply solder

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Both of these processes are permanent joining methods. Give TWO benefits of using permanent joints in electrical connections

Guaranteed better connection, better conductivity, better mechanical strength, less chance of disconnection, longevity

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Hardening Carbon steel - Purpose - Process

Increase resistance to wear - Heat, until it is red/critical temperature, quench, quick cooling process

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Tempering Carbon steel - Purpose - Process

To increase toughness/reduce brittleness - Heat, until oxides form, quench when appropriate ocide colour is visible

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Annealing Carbon steel - Purpose - Process

To soften/remove internal stresses/malleable - Heat, until it is red/critical temperature, allow to cool

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Describe how a split pattern for a handle would be made in a school workshop

Manufactured from wood/MDF, pattern cut and shaped slightly larger than required, cut down the centre, allow for thickness of cut, add location pins, seal and paint

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Describe the process of sand casting the carrying handle

Pattern appropriately placed in cope and drag, sprinkled with parting powder, sprue pins to create runner and riser, create gates, remove pattern and sprue pins, pour metal and allow to cool, remove casting and fettle

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When a casting is made it shrinks. State how this shrinkage is overcome

Make the pattern oversized

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In industrial commercial production the carrying handle would be die cast. Give TWO advantages of die casting over sand casting

Accuracy, speed of production, complexity of shape, self finishing, smoother finish on die-casting, die can be used repeatedly, economics of scale, die-casting less labour intensive

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Name a specific material that can be used to vacuum form the packaging for a CD player - Explain why this material is suitable for vacuum forming

ABS/Acrylic/Polystyrene/PVC/Polythene - Low melting/softening point, so can be easily moulded, rigid, to secure/protect CD player once packaged

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The following materials were considered for the casing of the CD player: Aluminium, ABS. Evaluate the suitability of these materials to determine the most appropriate material for the casing

Aluminium - lightweight, corrosion resistant, easily formed in to a variety of shapes, expensive, electrical conductor, not major drawbacks but cause higher costs - ABS - tough, hard, lightweight, inexpensive, electrical insulator, flammable

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Engineering May 2012 Questions and Markscheme answers

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Other cards in this set

Card 2

Front

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Card 3

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Card 4

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Back

Card 5

Front

Back

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