KCSE Paper – Metalwork Paper 1 (2008)
August 7, 2011 KCSE Exams
SECTION A (40 marks)
Answer all the questions in this section.
1. (a) State four reasons for wearing protective clothing when grinding metal. (2 marks)
(b) Differentiate between public and private sectors as applied to the manufacturing Industry. (2 marks)
2. (a) State three ways of classifying files. (1 ½ marks)
(b) State two uses of each of the following tools:
(i) Cross cut chisel;
(ii) Half round file. (2 marks)
3. (a) State four uses of trammel in sheet metal work. (2 marks)
(b) Sketch and name the most suitable hand tool for cutting internal curves in Tin plate. (1 ½ marks)
4. Differentiate between physical and mechanical properties of metal and give two examples of each property. (4 marks)
5. (a) Explain the following faults as applied to gas welding:
(ii) flashback. (2 marks)
(b) State two causes of each of the faults in (a) above. (2 marks)
6. Use labeled sketches to show three uses of vernier calipers. (4 ½ marks)
7. With the aid of labeled sketches, outline the steps of punching a hole in a metal Bar on an anvil. (3 marks)
8. (a) State four differences between soft soldering and brazing. (2 marks)
(b) Describe three method of strengthening an edge of sheet metal. (3 marks)
9. (a) State two advantages of pop-riveting over snap-head riveting. (2 marks)
(b) State three reasons for finishing metal surfaces. (1 ½ marks)
10. Figure 1 show two orthographic views of a machined block drawn in first angle Projection.
Sketch the isometric view of the block taking X as the lowest point. (5 marks)
KCSE PAPER – SECTION B – (60 marks)
Answer question 11 and any other three question from this section.
Candidates are advised to spend not more then 25 minutes on question 11.
11. Figure 2 shows two views of a machined block drawn in first angle projection. Draw full Size in third angle projection:
(a) A section views along the cutting plane A-A.
(b) A section view along the cutting plane B-B. (15 marks)
12. Figure 3 shows a scoop handle and the development of the body.
(a) Sketch a pictorial view of the folded body with the handle brazed to the body. (5 marks)
(b) Outline the procedure of:
(i) Folding the scoop body;
(ii) Making the handle;
(iii) Brazing the handle to the body. (10 marks)
13. (a) Name the most suitable metals for making each of the following items and State two reasons for each choice;
(i) Soldering wire;
(ii) Surface plate;
(iii) Twist drill. (4 ½ marks)
(b) Illustrate each of the following forms of metal supply and state two applications Of each form:
(i) Zed bar;
(ii) Angle bar;
(iii) Square pipe. (4 ½ marks)
(c) Describe each of the following metal finishing processes:
(iii) Planishing. (6 marks)
14. Figure 4 shows a single cover riveted butt joint.
(a) Using the information given in the diagram, determine:
(i) The rivet shank diameter;
(ii) Shank length for a snap-head rivet;
(iii) Edge distance A;
(iv) Pitch distance B; (6 ½ marks)
(b) State three factors to consider when selecting the type of rivet head used. (1 ½ marks)
(c) Outline the procedure of riveting the joint using snap-head rivets. (7 marks)
15. (a) State three differences between cold and hot forging. (3 marks)
(b) Figure 5 shows a chain support eye to be made from a 6 mm silver steel rod.
(i) Determine the total length of the rod
(ii) Outline the procedure of forming the eye
(iii) Outline the procedure of cutting the thread. (12 marks)