Cambridge IGCSE Design and Technology 0445 — 2016 Oct/Nov Paper 3 · Variant 2

This document consists of 18 printed pages and 2 blank pages. DC (NF/FD) 117567/1 © UCLES 2016 [Turn over Cambridge International Examinations Cambridge International General Certificate of Secondary Education * 3 3 3 4 6 4 8 9 1 4 * DESIGN AND TECHNOLOGY 0445/32 Paper 3 Resistant Materials October/November 2016 1 hour Candidates answer on the Question Paper. No Additional Materials are required. 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 an HB pencil for any diagrams, graphs or rough working. Do not use staples, paper clips, glue or correction fluid. 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. At the end of the examination, fasten all your work securely together. The number of marks is given in brackets [ ] at the end of each question or part question. The total of the marks for this paper is 50.

2 0445/32/O/N/16 © UCLES 2016 Section A Answer all questions in this section. 1 Fig. 1 shows three saws used to cut wood. A B C Fig. 1 Name each of the saws A, B and C. A … B … C … [3]

3 0445/32/O/N/16 © UCLES 2016 [Turn over 2 Complete the table below by naming a specific material for each product. Product metal spoon metal wire plastic bowl Specific material [3] 3 Complete the drawing below to show a half lap joint. [2]

4 0445/32/O/N/16 © UCLES 2016 4 Complete the table below by naming each of the marking out tools. Marking out tool Name [3] 5 Fig. 2 shows a length of wood with three slots marked out. Fig. 2 (a) Give one reason why the lines would be marked out using a marking knife rather than a pencil. … [1] (b) Name a tool that could be used with a marking knife to mark all the lines at the same angle across the grain of the wood. … [1]

5 0445/32/O/N/16 © UCLES 2016 [Turn over 6 Fig. 3 shows two products made from plastic. channel container Fig. 3 Name the moulding process used to make each product. channel … [1] container … [1] 7 Fig. 4 shows a mortise with a square haunch. square haunch Fig. 4 (a) Draw a square haunch tenon that would fit into the square haunch mortise shown in Fig. 4. [2] (b) Describe the purpose of the square haunch. … [1]

6 0445/32/O/N/16 © UCLES 2016 8 Fig. 5 shows two different types of drill bit. A B Fig. 5 Name the drill bits A and B shown in Fig. 5. A … B … [2] 9 Complete the table by naming each tool or item of equipment used to cut sheet metal. Tool or item of equipment Name [3]

7 0445/32/O/N/16 © UCLES 2016 [Turn over 10 Fig. 6 shows two pieces of resistant material. Fig. 6 Name a suitable adhesive that could be used to join the two pieces of material shown above when made from: (a) pine … (b) steel … [2]

8 0445/32/O/N/16 © UCLES 2016 Section B Answer one question in this section. 11 Fig. 7 shows views of a clock used to teach children how to tell the time. The clock face is made from plywood and the clock hands are made from acrylic. The clock hands will be moved by the teacher. 12 250 Ø Fig. 7 (a) Give two specification points for the clock. 1 … 2 … [2] (b) (i) Fig. 8 shows the clock face marked out on a sheet of 12 thick plywood. The shape will be cut out using a jigsaw. Fig. 8 Give two safety precautions that must be taken when using a jigsaw. 1 … 2 … [2]

9 0445/32/O/N/16 © UCLES 2016 [Turn over (ii) Describe how the shape could be made round and the edges made smooth after it has been cut out with a jigsaw. … … … [2] (c) Fig. 9 shows one clock hand marked out on 5 thick acrylic. 80 30 Fig. 9 Use sketches and notes to show how the clock hand could be cut out and the edges finished to a high quality. [4] (d) Give one benefit of using acrylic for the clock hands. … [1]

10 0445/32/O/N/16 © UCLES 2016 (e) Add sketches and notes to the drawing below to show how the clock hands could be fitted to the clock face. The teacher must be able to move the clock hands. clock hands: 5 thick acrylic clock face: 12 thick plywood [3] (f) The numbers on the clock face could be designed by CAD (Computer Aided Design) and made using CAM (Computer Aided Manufacture). Give one benefit of using: CAD to design the numbers; … [1] CAM to make the numbers. … [1]

11 0445/32/O/N/16 © UCLES 2016 [Turn over (g) Use sketches and notes to show how the clock could be made to stand on its own. Include details of materials, constructions and fittings used. [5] (h) Use sketches and notes to show how the clock could be made to fit to a wall instead of standing on its own. Include details of materials, constructions and fittings used. [4]

12 0445/32/O/N/16 © UCLES 2016 12 Fig. 10 shows a wall-mounted shelf unit. 500 500 140 shelves: veneered chipboard 15 thick end frames: mild steel rod Ø8 Fig. 10 (a) Give two advantages of using veneered chipboard rather than solid wood for the shelves of the wall-mounted shelf unit. 1 … 2 … [2] (b) Fig. 11 shows a wooden former around which the mild steel rod will be bent to the shape of the end frame. baseboard: 25 thick MDF Fig. 11 (i) Add sketches and notes to Fig. 11 to show how the mild steel rod could be held against the former while it is bent to shape. [3]

13 0445/32/O/N/16 © UCLES 2016 [Turn over (ii) When shaping the mild steel rod it can become work hardened. Explain what is meant by the term ‘work hardened’. … … … [2] (c) Fig. 12 shows the two ends of a length of Ø8 mild steel rod. The mild steel rod has been bent to the shape of the end frame. The ends will be brazed together. joint to be brazed Fig. 12 Use sketches and notes to show how the ends of the mild steel rod could be brazed together. Include details of how the ends would be prepared before they are brazed. [8]

14 0445/32/O/N/16 © UCLES 2016 (d) Use sketches and notes to show how the veneered chipboard shelves could be fixed to the end frames made from mild steel rod. Additional materials, fittings and fixings may be used. [6] (e) Give one reason why each of the materials used to make the wall-mounted shelf unit shown in Fig. 10 could be considered to be environmentally friendly. Mild steel … [1] Veneered chipboard … [1]

15 0445/32/O/N/16 © UCLES 2016 [Turn over (f) Fig. 13 shows a wall-mounted shelf unit with veneered chipboard sides rather than mild steel end frames. Fig. 13 Give two reasons why the designer has decided to use veneered chipboard sides rather than mild steel end frames. 1 … 2 … [2]

16 0445/32/O/N/16 © UCLES 2016 13 Fig. 14 shows views of an incomplete design for a towel holder made mainly from oak. 195 30 45 Fig. 14 (a) Give two properties of oak that make it suitable for the towel holder. 1 … 2 … [2] (b) Fig. 15 shows details of one rail marked out, ready to be shaped.  ZDVWH Fig. 15 Use sketches and notes to show how the waste wood could be removed and the surfaces made flat and smooth. Include details of how the rail would be supported while it is shaped. [5]

17 0445/32/O/N/16 © UCLES 2016 [Turn over (c) Use sketches and notes to show how all the rails could be: • connected to the back of the towel holder; • allowed to swing as shown in Fig. 14; • spaced apart. Include details of materials, constructions and fittings used. [8] (d) Use sketches and notes to show how the towel holder could be fitted to a wall. Holes must not be drilled in the front of the towel holder. Include details of materials, constructions and fittings used. [5]

18 0445/32/O/N/16 © UCLES 2016 (e) (i) Give two reasons why a clear polyurethane varnish would be a suitable finish for the towel holder. 1 … 2 … [2] (ii) Describe three stages to prepare the parts of the towel holder to take a clear polyurethane varnish finish. 1 … 2 … 3 … [3]

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20 0445/32/O/N/16 © UCLES 2016 BLANK PAGE 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. To avoid the issue of disclosure of answer-related information to candidates, all copyright acknowledgements are reproduced online in the Cambridge International Examinations Copyright Acknowledgements Booklet. This is produced for each series of examinations and is freely available to download at www.cie.org.uk after the live examination series. 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.

® IGCSE is the registered trademark of Cambridge International Examinations. This document consists of 5 printed pages. © UCLES 2016 [Turn over Cambridge International Examinations Cambridge International General Certificate of Secondary Education DESIGN AND TECHNOLOGY 0445/32 Paper 3 Resistant Materials October/November 2016 MARK SCHEME Maximum Mark: 50 Published 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, which would have considered the acceptability of alternative answers. Mark schemes should be read in conjunction with the question paper and the Principal Examiner Report for Teachers. Cambridge will not enter into discussions about these mark schemes. Cambridge is publishing the mark schemes for the October/November 2016 series for most Cambridge IGCSE®, Cambridge International A and AS Level components and some Cambridge O Level components.

Page 2 Mark Scheme Syllabus Paper Cambridge IGCSE – October/November 2016 0445 32 © UCLES 2016 Section A 1 A rip saw, cross cut saw, panel saw (1) B tenon saw, dovetail saw [not backsaw] (1) C coping saw (1) [3] 2 Metal spoon: stainless steel (1) Metal wire: copper, aluminium (1) Plastic bowl: polypropylene, PP, HDPE (1) [3] 3 Award 0–2 dependent upon accuracy of sketch 0–2 [2] 4 Marking gauge (1) Scriber (1) Odd legs, odd leg calipers [not calipers] (1) [3] 5 (a) Lines to be sawn down use a marking knife. Wood fibres are cut [1] (b) Sliding bevel, mitre square, combination square [1] 6 Channel: extrusion (1) Container: blow moulding (1) [2] 7 (a) Sketch shows tenon (1) Sketch shows haunch (1) [2] Must be shown in correct orientation (b) To lock the tenon to prevent it from moving/twisting stability/ more gluing area/increased strength [1] 8 A Countersink drill (1) B Flat bit (1) [2] 9 [Cold] chisel (1) Guillotine (1) Tinsnips (1) [3] 10 (a) Pine: wide range of adhesives. Accept generic and trade names such as PVA and Evo Stik Resin W, Cascamite, synthetic resin, Gorilla glue, contact/impact adhesive (1) (b) Epoxy resin, Araldite (1) [2]

Page 3 Mark Scheme Syllabus Paper Cambridge IGCSE – October/November 2016 0445 32 © UCLES 2016 Section B 11 (a) 2 specification points: must be large enough to be seen at distance, must have clear and easy to read numbers, must be able to move hands freely, must be freestanding/wall-mounted Accept any sensible spec. points 2×1 [2] (b) (i) 2 safety precautions include: wear safety glasses, mask, secure work, no trailing leads, tie hair/clothing out of the way, no obstructions below work piece 2×1 [2] (ii) Award 0–2 on quality of description: for example, use of sanding disc fully described with plywood rotated against the disc to ensure smooth finish. Accept use of files. [2] (c) Use of: coping saw, Hegner saw or equivalent, junior hacksaw saw to cut out waste (1) files to achieve shape (1) wet and dry paper to achieve smooth surface (1) polishing mop/compound to produce high quality finish (1) [4] (d) Benefit: range of colours, inherent colours/self-finished, attractive [1] (e) Some form of screw, bolt, pin or dowel (1) Hands retained at back and front (1) Spacers/washers to allow for movement (1) [3] (f) CAD to design numbers: easy to change design, wide variety of fonts to try out. [1] CAM to make numbers: extremely accurate, more professional appearance and quicker to produce than alternative methods, identical quality. [1] Not faster/quicker without qualification. (g) Some form of practical stand or support 0–3 For maximum marks the stand/support must be clearly drawn showing how it functions Materials, fittings and constructions 0–2 [5] (h) Some form of practical bracket attached to the back of the clock with provision for fixing to wall. Alternative method: plate with keyhole slot. Award 0–2 dependent upon accuracy of drawing. 0–2 Materials, fittings and constructions 0–2 [4]

Page 4 Mark Scheme Syllabus Paper Cambridge IGCSE – October/November 2016 0445 32 © UCLES 2016 12 (a) 2 advantages: cheaper, does not warp/shrink, more readily available. 2×1 [2] (b) (i) Use of blocks and pegs to position the mild steel rod against former 0–2 Retention of end of rod (1) [3] (ii) Work hardened: metal is shaped by hammering (1) as a result metal becomes harder (1) [2] (c) Preparation of ends before brazing: degreasing, filing, emery cloth 0–2 Accept 4 stages in brazing process: Clamp ends together Set up on hearth Apply flux Apply heat Apply brazing rod/spelter Allow to cool 4×1 Award 0–2 for technical accuracy of sketches 0–2 [8] (d) Method of fixing allows for use of brackets, modifications to length and/or width of shelves. Practical idea 0–2 Fix to shelf 0–1 Fix to end frame 0–1 Details of materials, fittings and fixings 0–2 [6] (e) 2 reasons about aesthetics: for example, different appearance is more interesting, prefers combination of materials, lighter appearance 2×1 [2] (f) Environmentally friendly materials: mild steel can be melted down and recycled [1] veneered chipboard uses waste materials not requiring trees to be chopped down [1]

Page 5 Mark Scheme Syllabus Paper Cambridge IGCSE – October/November 2016 0445 32 © UCLES 2016 13 (a) 2 properties: very hardwearing, tough, water resistant, attractive, gives a good finish 2×1 [2] (b) Method of support: vice or bench stop shown (1) Use of saw (1) Use of plane to remove waste (1) Use of glasspaper to make smooth (1) Technical accuracy: for example, named plane, saw, different grades of glasspaper 0–1 [5] (c) Some sort of bracket to which the rails can be attached 0–2 Use of pin, rod or dowel through rails to allow them to rotate 0–2 Method to keep rails apart: some form of spacer 0–2 Details of materials and fittings used 0–2 [8] (d) Practical idea. For maximum marks the method must be clear 0–2 Holder must not rotate 0–1 Some form of bracket attached to the back of the towel holder with provision for fixing to wall. Alternative method: plate with keyhole slot. Materials, fittings and constructions 0–2 [5] (e) (i) 2 reasons: hardwearing, attractive, allows natural colour/grain of wood to be seen, waterproof, protects wood 2×1 [2] (ii) 3 stages include: use of glasspaper [medium grade] wipe down surface/ remove dust use of glasspaper [fine grade] use of cork rubber/block stated 3×1 [3]