Cambridge IGCSE Design and Technology 0445 — 2008 May/June Paper 3 · Variant 1

READ THESE INSTRUCTIONS FIRST Write your Centre number, candidate number and name on all the work you hand in. Write in blue or black pen. You may use a soft pencil for any diagrams, graphs or rough working. Do not use staples, paper clips, highlighters, glue or correction fl uid. DO NOT WRITE IN ANY BARCODES. Section A Answer all questions in this section. Section B Answer one question in this section. You may use a calculator. The total of the marks for this paper is 50. The number of marks is given in brackets [ ] at the end of each question or part question. DESIGN AND TECHNOLOGY 0445/03 Paper 3 Resistant Materials May/June 2008 1 hour Candidates answer on the Question Paper. No Additional Materials are required. To be taken together with Paper 1 in one session of 2 hours 15 minutes. UNIVERSITY OF CAMBRIDGE INTERNATIONAL EXAMINATIONS International General Certifi cate of Secondary Education This document consists of 16 printed pages. [Turn over IB08 06_0445_03/RP © UCLES 2008 *6553526778* For Examiner’s Use Total Section A Section B www.XtremePapers.com

2 0445/03/M/J/08 © UCLES 2008 For Examiner’s Use Section A Answer all questions in this section. 1 500 waste line to be marked Name the correct tool you would use to carry out the following processes to the length of solid wood shown above: (a) marking a line parallel to the edge; … [1] (b) removing the waste wood; … [1] (c) checking the edge for fl atness. … [1] 2 Complete the table below by giving the appropriate item, fi nish or purpose. Item Finish Purpose saucepan PTFE (Tefl on®) galvanised prevents rust copper jewellery hard, colourful and protective [3]

3 0445/03/M/J/08 © UCLES 2008 [Turn over For Examiner’s Use 3 State how the clear acrylic rod shown in Fig. 1 could be joined permanently to the acrylic base. Fig. 1 … [1] 4 Give one benefi t of using a contact (impact) adhesive when joining a plastic laminate to a manufactured board. … [1] 5 Fig. 2 shows a metric micrometer and a close-up view of the sleeve and thimble. sleeve sleeve thimble thimble 0 5 10 25 20 15 10 Fig. 2 State the exact reading shown to one hundredth of a mm (0.01 mm). … [3]

4 0445/03/M/J/08 © UCLES 2008 For Examiner’s Use 6 Complete the sketch below to show a corner bridle joint. [3] 7 Fig. 3 shows two different types of nut. Fig. 3 Give one advantage of using each type of nut. Advantage of wing nut … [1] Advantage of hexagonal nut … [1] 8 Paint can be applied by brush or spray. (a) State one advantage, other than speed, of using a spray to apply paint. … [1] (b) Describe one safety precaution you would need to take when spray painting. … [1]

5 0445/03/M/J/08 © UCLES 2008 [Turn over For Examiner’s Use 9 Name the type of chisel used to cut into corner A shown below. A … [1] 10 Complete the table below by naming the process by which each of the plastic products would be made and give a different material for each of the products shown. Plastic product cap from a toothpaste tube egg carton lemonade bottle Process Material [6]

6 0445/03/M/J/08 © UCLES 2008 For Examiner’s Use Section B Answer one question from this section. 11 Fig. 4 shows an incomplete design for a Compact Disc (CD) rack made from acrylic. 232 Fig. 4 (a) Give two advantages of using acrylic rather than wood for the CD rack shown in Fig. 4. 1 … [1] 2 … [1] (b) Give two benefi ts of using a template when marking out the shelves for the CD rack. 1 … [1] 2 … [1]

7 0445/03/M/J/08 © UCLES 2008 [Turn over For Examiner’s Use (c) Fig. 5 shows one shelf of the CD rack. 200 shelf: equilateral triangle 200 side holes Ø6 Fig. 5 (i) Use sketches and notes to design a jig that could be used when drilling the three holes in each of the thirteen shelves accurately. [3] (ii) Describe one safety feature of your jig in use. … … [1]

8 0445/03/M/J/08 © UCLES 2008 For Examiner’s Use (d) Fig. 6 shows a length of acrylic from which fi ve shelves will be produced. 176 620 Fig. 6 SCALE 1:4 (i) Draw on Fig. 6 to show how fi ve shelves could be marked out ready to be sawn. [4] (ii) Give one reason why a felt-tip pen would be used to mark out the acrylic rather than a scriber. … [1] (iii) Use sketches and notes to show how one shelf could be sawn from the length of acrylic shown in Fig. 6. Include the following details: ● the method of holding the acrylic securely; ● the name of the saw used. [4]

9 0445/03/M/J/08 © UCLES 2008 [Turn over For Examiner’s Use (iv) Describe four stages used to fi nish the edges of the acrylic shelves after they have been sawn to shape. 1 … … 2 … … 3 … … 4 … … [4] (e) Fig. 7 shows the top three shelves located on Ø6 rods. Use sketches and notes to show how each shelf could be spaced to enable CDs to be stored. Fig. 7 [4]

10 0445/03/M/J/08 © UCLES 2008 For Examiner’s Use 12 Fig. 8 shows a wind speed indicator for use in school. As the wind blows, the wind fl ap is lifted and the speed can be read off the measuring scale. The device is made from mild steel except for the wind fl ap which is made from aluminium. M E A S U R I N G S C A L E base 10 thick sheet 2 thick support arm Ø8 WIND FLAP direction of wind Fig. 8 (a) Describe how the weight of mild steel and aluminium has been considered in the design of the wind speed indicator. Mild steel … [1] Aluminium … [1] (b) The mild steel used for the support arm was annealed before it was bent to shape. (i) State the effects that annealing has on mild steel. … … [2] (ii) Describe how the Ø8 mild steel rod would be annealed. … … [2] (iii) Use sketches and notes to show how the Ø8 mild steel rod could be bent to shape. [4]

11 0445/03/M/J/08 © UCLES 2008 [Turn over For Examiner’s Use (c) The end of the support arm is joined to the base by means of a screw thread. Use sketches and notes to describe the process involved in cutting a screw thread: (i) on the end of the support arm; [3] (ii) in the base. [3] (d) Use sketches and notes to show how the wind fl ap could be prevented from slipping off the end of the support arm. [3]

12 0445/03/M/J/08 © UCLES 2008 For Examiner’s Use (e) Fig. 9 shows the shape of the measuring scale partly marked out on 2 mm thick mild steel sheet. Fig. 9 Name the correct tool that could be used to: (i) remove the waste metal; … [1] (ii) produce a smooth edge to the curved shape. … [1] (f) Use sketches and notes to show how the measuring scale could be attached to the support arm. [4]

13 0445/03/M/J/08 © UCLES 2008 [Turn over For Examiner’s Use 13 Fig. 10 shows details of a child’s toy. head body legs three separate parts Tray: two pieces of 6 mm manufactured board glued together space for teddy bear parts Fig. 10 (a) The separate parts of the teddy bear could be made from a plastic material or from wood. Give two advantages of using a plastic material rather than wood. 1 … [1] 2 … [1] (b) Give two advantages of constructing the tray from two separate pieces rather than one piece of manufactured board. 1 … [1] 2 … [1]

14 0445/03/M/J/08 © UCLES 2008 For Examiner’s Use (c) Use sketches and notes to show how the space for the teddy bear parts could be cut out of the manufactured board. Include the following details: ● the name of the saw you would use; ● the method of smoothing the edges to the finished shape; ● one safety precaution you would take while involved in any of these processes. [6] (d) The two pieces of 6 mm thick manufactured board for the tray will be glued together using PVA wood adhesive. (i) Describe how the adhesive would be applied. … [1] (ii) Describe how the two pieces of manufactured board would be held together while the adhesive sets. … [1] (iii) State approximately how long it would take for the joint to set. … [1]

15 0445/03/M/J/08 © UCLES 2008 [Turn over For Examiner’s Use (e) The three separate parts of the teddy bear are to be stored in the box shown in Fig. 11. The tray will be used as the lid of the box. head body legs three separate parts Fig. 11 corner A Tray (i) Use sketches and notes to show how the tray could be supported inside the box. The tray must be level with the top of the box. [4]

16 Permission to reproduce items where third-party owned material protected by copyright is included has been sought and cleared where possible. Every reasonable effort has been made by the publisher (UCLES) to trace copyright holders, but if any items requiring clearance have unwittingly been included the publisher will be pleased to make amends at the earliest possible opportunity. University of Cambridge International Examinations is part of the Cambridge Assessment Group. Cambridge Assessment is the brand name of University of Cambridge Local Examinations Syndicate (UCLES), which is itself a department of the University of Cambridge. 0445/03/M/J/08 © UCLES 2008 For Examiner’s Use (ii) Complete the drawing below to show a suitable joint, other than a butt joint, for corner A. [3] (iii) Name of joint at corner A. … [1] (iv) Name two tools you would use to mark out the joint at corner A. 1 … [1] 2 … [1] (v) Name two tools you would use to cut out the joint at corner A. 1 … [1] 2 … [1]

UNIVERSITY OF CAMBRIDGE INTERNATIONAL EXAMINATIONS International General Certificate of Secondary Education MARK SCHEME for the May/June 2008 question paper 0445 DESIGN AND TECHNOLOGY 0445/03 Paper 3 (Resistant Materials), maximum raw mark 50 This mark scheme is published as an aid to teachers and candidates, to indicate the requirements of the examination. It shows the basis on which Examiners were instructed to award marks. It does not indicate the details of the discussions that took place at an Examiners’ meeting before marking began. All Examiners are instructed that alternative correct answers and unexpected approaches in candidates’ scripts must be given marks that fairly reflect the relevant knowledge and skills demonstrated. Mark schemes must be read in conjunction with the question papers and the report on the examination. • CIE will not enter into discussions or correspondence in connection with these mark schemes. CIE is publishing the mark schemes for the May/June 2008 question papers for most IGCSE, GCE Advanced Level and Advanced Subsidiary Level syllabuses and some Ordinary Level syllabuses. www.XtremePapers.com

Page 2 Mark Scheme Syllabus Paper IGCSE – May/June 2008 0445 03 © UCLES 2008 1 (a) Marking gauge. [1] (b) Jack or trying plane. [accept plane only] [1] (c) Rule or straight edge. [1] 2 Item Finish Reason Saucepan PTFE (Teflon) Non-stick Bucket, watering can, bin, gate, nails, screws, bolts, chains Galvanised Prevents rust Copper jewellery Clear lacquer, “Ercolene”, enamel Hard, colourful and protective [3] 3 Clear acrylic rod joined by means of Tensol, acrylic cement, plastic cement. [1] 4 One benefit includes: no need to clamp / immediate joint. [1] 5 Above datum = 10 mm [1] Below datum = 0.5 mm [1] Highest line on thimble below datum = 0.16 [1] Reading = 10.66 [3] 6 Quality and accuracy of correct joint. (0–3) [3] 7 Wing nut can be tightened by hand without use of spanner, easier to undo. [1] Hexagonal nut can have great pressure applied using a spanner, can be screwed on tight. [1] 8 (a) Advantage of spray: more consistent / smoother finish / no brush strokes, covers wider area, no hairs from brush. [1] (b) Safety precaution: well ventilated room / face mask / goggles. [1] 9 Bevel-edge chisel. [1]

Page 3 Mark Scheme Syllabus Paper IGCSE – May/June 2008 0445 03 © UCLES 2008 10 Plastic product Process Material cap off a toothpaste tube Injection moulding ABS polypropylene HDPE cellulose acetate egg carton Vacuum forming polythene polystyrene lemonade bottle Blow moulding HDPE [6] 11 (a) Two advantages include: self finished, colour inherent, attractive. (1) [1] (b) Two benefits include: speed, accuracy, saves space, saves material. (1) [1] (c) (i) Locate jig to shelf. (1) Position for holes located/drilled. (1) Secure while drilling. (1) [3] (ii) Safety feature must relate to use of the jig. [1] Award feature even if jig is inappropriate.

Page 4 Mark Scheme Syllabus Paper IGCSE – May/June 2008 0445 03 © UCLES 2008 (d) (i) Tesselating shapes. (1) Waste between shapes. (1) Accuracy/proportion. (0–2) [4] (ii) Chinagraph pencil mark can be erased, scriber makes a scratch in surface. [1] (iii) Method of holding: vice, G cramp, bench hook. (1) Correctly named saw: vibro, Hegner, tenon, coping, hacksaw. (1) Accuracy/quality of answer. (0–2) [4] (iv) 4 stages include: draw filing, scraper, wet and dry paper, polishing compound/wheel. (4x1) [4] (e) Use of ‘spacer’ or similar technique. Accept interference fit. (1) Details of how ‘spacer’ is constructed into rack. (1) Quality/accuracy of design. (0–2) [4] 12 (a) Mild steel will give stability for the base. [1] Aluminium is light and will allow the wind to blow the wind flap. [1] (b) (i) Annealing alters the internal structure of the metal, relieves internal stresses and softens the metal so that it can be worked. [2] (ii) Steel is heated. (1) Steel is allowed to cool. (1) [2] (iii) Use of vice or anvil. (1) Use of former and hammer/mallet. (1) Accuracy/quality of sketch. (0–2) [4] (c) (i) End of rod tapered. (1) Die and dieholder. (1) Method: cut and turn back. Accept taper tap followed by second tap. (1) [3] (ii) Tapping size drilled hole in base. (1) Tap and tap wrench. (1) Method: cut and turn back. (1) [3]

Page 5 Mark Scheme Syllabus Paper IGCSE – May/June 2008 0445 03 © UCLES 2008 (d) Nut and washer or rivet, split pin, rubber stopper, mushroom end over. (1) Accuracy/quality of sketch. (0–2) [3] (e) (i) Tin snips or abra file saw. [1] (ii) Half round file. [1] (f) ‘U’ bracket or similar riveted using countersunk rivets/pop rivets/machine screws. (0–3) [Glue or soldering only = 0 marks.] Non-protrusion on scale side. (1) [4] 13 (a) Two advantages include: hardwearing, colourful, inherent colour, no splinters, will not warp or rot, non toxic, more child friendly. (1) [1] (b) Two advantages include: quicker to produce, more accurate, easier to finish, no need to use a milling machine or router, easier to construct. (1) [1] (c) Correctly named saw: coping, Hegner, Scroll. (1) Correct method of sawing: drilling hole large enough for saw blade to enter. (1) Edges smoothed by means of a file. (1) Safety precaution appropriate to relevant process. (1) Accuracy/quality of sketch. (0–2) [6] (d) (i) Adhesive applied by brush or thin stick evenly over both surfaces. [1] (ii) Pieces held together by G cramps, vice, weights on top. [1] (iii) Approximate setting time 1–3 hours. [1] (e) (i) Level with top. (1) Means of support: rebate, applied bead – correct principle. Use of router. (1) Accuracy/quality of sketch. (0–2) [4] (ii) Quality of drawing showing appropriate joint. [3] (iii) Appropriately named joint: rebate, mitre, dowel, finger or comb, dovetail. [1] (iv) Two marking out tools include: pencil, rule, try square, marking/cutting gauges. [1] Accept any correct tool appropriate to the joint shown in (i). [1] (v) Two cutting tools include: tenon/dovetail saws, chisel, coping saw. [1] Accept any correct tool appropriate to the joint shown in (i). [1] Accept holding tools: cramps, bench hook, vice if appropriate. If joint is inappropriate in (ii) award marks for correct tools in parts (iv) and (v).