GCSE Resistant Materials Past Examination Questions Taken from papers in 2005, 2006, 2007, 2008, 2009, 2010 No 1.
Question Image : Wooden Salt Mill
The outside profile of the salt mill has been turned between centres on a wood turning lathe.
Marks
3
Give three risks associated with turning wood on a lathe.
Answer 1. 2. 3. 2.
The wooden salt mill has been finished in varnish. State ONE good reason for using this type of finish
1
Answer 3
Manufacturers often produce products in batches. Explain TWO reasons why many companies prefer to produce products in batches
2
Answer 1. 2. 4.
A manufacturer needs to obtain sales information from retailers. State ONE electronic method that could be used to do this. Answer 1.
1
5.
ICT is used extensively in manufacturing industries. Identify SIX ways in which ICT can provide more efficient design, manufacturing and sales. Answer
6
1. 2. 3. 4. 5. 6. 6.
Image : Bleach bottle The bleach bottle shown is made from high density polythene which is a thermoplastic. 3 Give THREE properties of HDPE that make this a suitable plastic for this type of container Answer 1. 2. 3.
7.
Describe TWO differences between thermoplastics and thermosetting plastics
2
Answer 1. 2. 8.
Name a suitable manufacturing process used to produce a bleach bottle of the type shown Answer 1.
1
9.
Texture can be moulded onto the polythene body and the cap. Explain TWO advantages of adding texture in this way Answer
2
1. 2. 10. Most UK products have a Kite Mark or British Standards Mark attached. State THREE benefits to the consumer of being able to buy producst with these markings Answer
Two specification points for the bottle are • It should be able to hold different flavoured drinks • Show that the bottle has not been opened before its been purchased Identify TWO specification points that would be suitable for a bottle of this type under each of the following headings • Material • Market • Function (explain the reason for each choice)
6
Answer Form (Materials) 1. 2.
Market 1. 2. Function 1. 2.
12. The main body of the plastic water bottle has a separate printed label. Give THREE reasons for using labels of this type rather than printing directly onto the plastic Answer
3
1. 2. 3.
13. The main body of the bottle is manufactured by blow moulding. Give TWO reasons why blow moulding is a suitable manufacturing process Answer 1. 2.
2
14
Image : Aluminium drinks can
4 Give FOUR properties of aluminium that makes it suitable for a drinks can of this type
Answer 1. 2. 3. 4.
15. The drinks can has been designed so they can be stacked upon each other. State TWO advantages og being able to stack drinks cans in this way.
2
Answer 1. 2. 16. Cans of this type have a ring pull to open them. State TWO disadvantages with this type of opening device Answer 1. 2.
2
17. Image : Bicycle
3
The bike frame is made from mild steel. State THREE properties of mild steel that make it suitable for a product of this type. Give a reason for each answer Answer 1. 2. 3.
18. Aluminium was also considered for the bike frame. State TWO disadvantages of aluminium compared to mild steel Answer
2
1. 2. 19. Bicycles of this type can also be made from carbon fibre. State THREE advantages of carbon fibre compared to mild steel Answer 1. 2. 3.
3
20
Explain THREE benefits to the environment of using a bicycle rather than a motor car as a mode of transport
3
Answer 1. 2. 3.
21. Image : Ball point pen
3 Two specification points for the ball point pen are that it must : 1. Clip into a shirt pocket when not being used. 2. Provide a steady flow of ink when being used Under each of the following headings give ONE further specification point and a reason for your choice. Answer Quality 1. Environment 1. Market 1. 22. The ball bearing for the tip is made from silver steel. One reason for using silver steel is that it will not rust. Give TWO other reasons why silver steel is a suitable material for the tip of this pen. Answer 1. 2.
2
23. The cap was maunufactured by injection moulding. State TWO reasons why injection moulding is a suitable manufacturing method. Answer
2
1. 2. 24. The body of the pen has been made form acrylic plastic. State TWO properties that makes acrylic a suitable plastic for the body of the pen. Answer
2
1. 2. 25. Image : Screwdriver with a metal handle
3 The blade of the screw driver is made from medium carbon steel that has been heat treated. State THREE health and safety risks associated with heat treatments Answer 1. 2. 3. 26. The blade of the screwdriver needs to be attached to the plastic handle. State TWO different ways of attaching the blade to the handle Answer
2
1. 2. 27. The handle is manufactured in high volumes by injection moulding. Give THREE reasons for using injection moulding to produce the handle. Answer 1. 2.
3
28. The manufacturer used CAD to design the handle. State THREE advantages of using CAD to manufacture to design the handle. Answer
3
1. 2. 3. 29
Image : Aluminium window frame The window frame shown is made from aluminium which is a non ferrous metal
Give THREE properties of aluminium that make it a suitable material for a window frame of this type
3
Answer 1. 2. 3. 30
Give FOUR differences between ferrous and non ferrous metals Answer 1. 2. 3. 4.
4
31
The window sill is made of mahogany which is a hardwood. StateTHREE reasons why hardwood is preferred to a softwood for the sill. Answer
3
1. 2. 3.
32
Image : Tap The image here is a conventional bathroom tap. Two specification points for the bathroom tap are that : • •
It must be easy to grip Indicate if the tap is to be used for hot or cold water
Under each of the following headings give one further specification point and the reason for your choice • Market • Environment • Quality Answer Market 1. 2. Environment 1. 2. Quality 1. 2.
3
33
The main body of the tap is made from brass which has then been chrome plated. Give TWO reasons why brass is a suitable material for a tap of this type Answer
2
1. 2.
34
The brass tap has been electro plated. Give TWO reasons why this type of tap is usually electro plated in this way Answer
2
1. 2. 35
The handle of the bathroom tap is made from acrylic plastic. State TWO reasons why acrylic plastic is a suitable material for the handle. Answer
2
1. 2. 36
Quality control checks are made at regular intervals on the plastic handle. State TWO quality checks that could be made on the plastic handle during the manufacturing process. Answer
2
1. 2. 37
The acrylic handle is suitable for high volume mass production using injection moulding. State TWO reasons why injection moulding is a suitable manufacturing process for the plastic handle Answer 1. 2.
2
38
Image : Wooden Steps
The hinge is made from brass which is an alloy .
2
State the TWO main metals required to make brass
Answer 1. 2. 39
State TWO main reasons why brass was preferred for the hinge in preference to mild steel. Answer
2
1. 2. 40
These wooden steps have been varnished. State THREE reasons why these steps would be varnished Answer
3
1. 2. 3. 41
Give THREE risks associated with using paint and varnish Answer 1. 2. 3.
3
42
Name TWO types of joint that would be suitable for the steps. Answer
2
1. 2. 43
The steps have been produced in high volume using CAM. Give THREE reasons why CAM is used to produce the steps. Answer
3
1. 2. 3. 44
The manufacture carries out regular quality checks during the manufacturing process. State TWO quality checks that would be carried out on the steps. Answer 1. 2.
45
A new Computer Aided Design (CAD) for the steps has been sent electronically by the designer to the manufacturer. State THREE advantages to the designer of sending designs electronically to the manufacturer. Answer 1. 2. 3. 4. 5.
2
46
Image : Wooden compost bin The image shows a compost bin for recycling household waste. Oak was considered to be the best material to use.
3
State THREE properties of oak that make it suitable for this type of product
Answer 1. 2. 3. 47
Chipboard was considered for the side panels to reduce the overall cost. State the main disadvantage with using chipboard for a product of this type Answer
1
1. 48
The wooden compost bin is secured to the ground by four metal feet at each corner made from mild steel. State ONE reason while mild steel was chosen for the metal feet instead of wood. Answer
1
1. 49
State TWO advantages to the environment of recycling household waste that is biodegradable Answer
3
1. 2. 50
Compost bins are sometimes manufactured from plastic. State a suitable plastic that would be suitable for compost bins of this size. Answer 1.
1
51
Image : Plastic compost bin State THREE advantages of using plastic for the compost bin in preference to wood.
3
Answer 1. 2. 3. 52
Many people prefer wooden compost bins because they are more aesthetically pleasing and wood is generally regarded as being more environmentally friendly than plastic. State ONE reason why a plastic compost bin could also be regarded as being an eco friendly product. Answer
3
1. 53
Image : Pine wooden drawer
This image shows part of a pine drawer for a typical bedroom drawer unit.
State THREE advantages of pine compared to using other hardwoods like Oak or Mahogany
3
Answer 1. 2. 3. 54
What type of wood joint is used for the drawer shown Answer 1.
1
55
State one advantage of dovetail joints Answer
1
1. 56
State main disadvantage of dovetail joints Answer
1
1. 57
Name TWO other joints that would be suitable for a drawer of this type. Your answer must not include Knock Down Joints. Answer
3
1. 2. 58.
Name THREE ways in which this drawer could be finished Answer
3
1. 2. 3. 59
The base of the drawer is made from plywood. State THREE advantages of making the base from plywood in preference to solid wood Answer
3
1. 2. 3. 60
The drawer knob is made from wood. Name TWO other suitable materials that could have been used for the drawer knob Answer 1. 2.
2
62
The company that makes the drawer wants to become more environmentally friendly. State FIVE ways in which the company could become more environmentally friendly Answer
5
1. 2. 3. 4. 5. 63
This bedroom range of furniture is usually updated on an annual basis. What would be the most suitable method of production for producing this type of product. Answer
1
1. 64
The manufacturer of the drawer uses the EPOS system. Give THREE pieces of information that can be obtained using the EPOS (bar code) system Answer
3
1. 2. 3. 65
Image : Plastic Torch The image shown is a plastic torch which has been manufactured from acrylic plastic. Give THREE properties of acrylic plastic that make it suitable for a product of this type
Bulb Reflector
3
Answer 1. 2. 3. 66
Name ONE other thermo-plastic that could be used to manufacture a product of this type Answer
1
1. 67
The bulb reflector cone is mass produced by vacuum forming. State TWO reasons why vacuum forming is a suitable manufacturing process for the bulb reflector. Answer
2
1. 2. 68
State THREE specification points that would be appropriate for a product of this type Answer
3
1. 2. 3. 69
The torch is claimed to be environmentally friendly. Name ONE feature of the torch that could justify this claim 1.
1
70
Image : Scissors made from mild steel
This scissors shown have been manufactured from mild steel.
State TWO properties that make mild steel suitable for a product of this type.
2
For each property , justify your answer Plastic dip coated handle
Answer 1. 2. 71
The handles have been coated in plastic by a process known as ‘dip coating’ . Give THREE reasons for plastic dip coating the handles of the scissors Answer
3
1. 2. 3. 72
Describe TWO reasons for electro-plating the blade of the scissors Answer 1. 2.
2
73
There is an environmental impact with the manufacture of most products. Describe THREE ways in which the manufacturer could reduce the environmental impact of manufacturing scissors of this type. Answer
3
1. 2. 3. 74
What is the carbon content of mild steel Answer
1
1. 75
Stainless steel was considered for the manufacture of these scissors. State TWO advantages of stainless steel compared to mild steel Answer
2
1. 2. 76
Stainless Steel contains iron and carbon. Name TWO other materials that are used in the production of stainless steel Answer
2
1. 2. 77
The two parts of the scissor is held together with a rivet. State one other method that could be used to join the scissors and one advantage with your choice Answers 1. Advantage >
1
78
Image : 3 pin plug This 3 pin plug has been made from thermosetting plastic State TWO reasons why thermosetting plastic has been used to manufacture this product
2
Answer 1. 2. 79
Name the thermosetting plastic used to manufacture products of this type Answer
1
1. 80
The pins are made from a non ferrous alloy. Name the metal and the materials used to manufacture this non ferrous alloy. Answer
3
1. 81
Very important information is printed onto the plastic of a 3 pin plug. State ONE piece of important information that is printed on a 3 pin plug and give a reason for your choice Answer
2
1. 82
State ONE quality symbol that could be found on a product of this type and explain why Answer
2
1. 83
The 3 pin plug has been manufactured from a thermosetting plastic. Name TWO other thermosetting plastics. For each answer identify ONE typical product made from that thermosetting plastic Answer 1.
Typical product
2.
Typical product
4
84
State the main disadvantage with thermosetting plastic with regards to the environment Answer
1
1.
85
Identify TWO quality checks that should be made on this product during the manufacturing process. One of your answers should relate to tolerance Answer
2
1. 2. 86
Image : CNC Vertical Milling Machine The image shown is a vertical milling machine (CNC)
This machine is often referred to as a 3 axis machine. Explain why ?
Answer
87
Name TWO typical 2 axis machine that could be found in a technology workshop Answer 1. 2.
1
88
CNC machines are controlled by a computer. State FIVE advantages of computer controlled equipment compared to machines that are manually operated. Answer
5
1. 2. 3. 4. 5. 89
Milling machines are regarded as ‘ wasting machines’ because they create waste material in the manufacturing process. Identify THREE different types of wasting processes associated with metal (do not include milling machines) Answer
3
1. 2. 3. 90
CNC milling machines use very hard cutting tools made from high carbon steel and high speed steel. State the carbon content of high carbon steel Answer
1
1. 91
Name TWO other materials that can be found in high speed steel in addition to iron and carbon Answer
2
1. 2. 92
Name TWO properties of high speed steel that makes it suitable for cutting tools Answer 1. 2.
2
93
Image : Hair dryer The hair dryer shown is made from ABS plastic State THREE properties of ABS plastic that make it suitable for a product of this type Answer 1. 2. 3.
94
State TWO ergonomic and/or anthropometric features that needs to be considered with a product of this type. Answer
2
1. 2. 95
State THREE safety precautions that should be included in the instructions with a product of this type Answer
3
1. 2. 3. 96
With regards to the environment, state the main advantage of making this product from ABS as opposed to a thermosetting plastic. Answer
1
1. 97
State ONE way in which the consumer can have confidence in the quality of this product Answer 1. 2.
1
98
If you carried out product analysis on this hairdryer by dis-assembly . State THREE reasons for carrying out product analysis of this type Answer
3
1. 2. 3. 99
Life cycle analysis is often referred to as ‘Cradle to Grave’. With the aid of a simple diagram identify the various stages of the life cycle that need to be considered when looking at the impact a product has on the environment
100 Have you found these questions easy to answer or difficult ? If you have found them easy, you have probably done adequate revision. If you have found them difficult, you probably have not done enough revision
6
TEN REVISION TIPS 1. At the very start of the examination. Quickly look through the entire paper before you start answering any questions. This should give you a feel good factor if you know the answer to most of the questions that you see and should help you relax ! 2. Read each question carefully. Many students make elementary errors because they DO NOT answer the actual question asked. 3. Look out for key words : If you see the word ‘name’ you can often get away with a one or two word answers. If you see the word identify or explain your answer will need to be more detailed. 4. Take your time and think about your answer before you write anything down. There are NO prizes for finishing the exam early. 5. Don’t ignore the simple and obvious answers. 6. If you can’t answer a question LEAVE IT and come back to it at the end. Answering other questions may trigger your memory. 7. Try and write neatly. Illegible handwriting could result in the loss of marks 8. Make sure your sketches are simple and neat. Ensure that all annotation refer to the specifications identified in the question 9. Never leave a question empty or unanswered. Take a guess which could gain you a few extra marks. 10. Read through your paper at the end. Don’t be afraid to change answers or add some extra thoughts that may have come to your mind during the examination
