Leaving Cert Engineering

Damian Keenan 2013

Instructions

• Answer Section A and Section B of Question 1 and FOUR other questions.

• All answers must be written in ink on the answer book supplied.

• Diagrams should be drawn in pencil.

• Squared paper is supplied for graphs, as required.

• Please label and number carefully each question attempted.

Q1 – You must answer Section a & section B

• Section A• Given 13 short questions – answer 10

• Read them all and pick the ten you know,

• Section B

• Basic principles of operation and applications of the Stirling engine from its invention in 1816 to its modern uses.”

Q2 Material Testing

• 2012 – • compare impact tests,• Tensile tests on different materials- explain

brittleness-elastic and plastic states• NDT, aircraft internal & external flaws – 2

types for each,• Name one for internal faults in welded joints,

Q2 Material Testing

2011• Metal fatigue & metal creep• Compare Hardness testers – method of

measurement & test material• Stress/ strain graph – find young's & proof

0.1% stress• NDT – Explain why NDT, Describe a test using

ultrasonic

Q2 Material Testing

• 2010• Why test metals till they break – id & describe

impact tester – how it works and why• Load/extension graph – find UTS 0.1% proof

stress• NDT – Describe Eddy Current testing – x ray

testing,

Q2 Material Testing

• 2009• Hardness tester with diamond – identify &

describe features• Stress/strain graph – id points on graph

(elastic, plastic)- describe shape of specimen at middle and end

• NDT – why use in cast bike engines, describe a test used on surface flaws in aluminium,

Q2 Material Testing

• 2008• Micoscopic vrs macroscopic examination of

metals – explain Creep, 2 factors that influence creep – compare indentors in brinnel & vickers

• Stress strain graph, find youngs & 0.1% proof stress

• Id NDT to determine surface & internal flaws on casting – describe test to locate internal defect

Q2 Material Testing

• 2006• Compare Brinell & Vickers, explain elastic

limit, id 2 factors to prevent early fatigue,• Load/extension graph – find tensile strength &

youngs• NDT – why used in industry, describe test to

detect internal flaws.

Q3 heat treatment & iron carbon

• 2012• Describe – Annealing, normalising, carburising• Describe the flame hardening shown & use,• Name different regions of graph – describe

eutectic and eutectoid

Q3 Heat treatment & Iron Carbon

• 2011• Describe Induction hardening - distinguish

grey & white cast iron – explain stress relieving in metals

• Name different regions of graph – outline cooling 0.4% steel from 900 degrees c

• Identify pyrometer and state function – describe how it works using the pictures,

Q3 heat treatment & iron carbon

• 2010• Compare Soaking & water cooling –

distinguish optical & thermo electric pyrometer – describe normalising

• Name different regions of graph – describe martinsite

• Describe heat treatment for slideways – describe this process

Q3 heat treatment & iron carbon

• 2009• Id 3 quenching media used in heat

treatments- discuss safety in case hardening, discuss induction hardening, what is pearlite,

• Id heat treatment processes as temp zones A,B,C,- explain Allotropy,

• Id pyrometer (thermo electric) – how does it work,

Q3 heat treatment & iron carbon

• 2008• Eutectic vrs eutectoid point, one method

measuring furnace temp, compare microstructures martensite & ferrite, explain recrystallisation in heat treatment

• Name different regions of graph – outline cooling 0.4% steel from 900 degrees c

• Describe pack carburising, outline flame hardening,

Q3 heat treatment & iron carbon

• 2007• 2 methods measuring furnace temperature,

describe allotropy, explain soaking in annealing, difference between grey and white cast iron,

• Name different regions of graph – describe eutectic and eutectoid (2012)

• Name 3 quenching media in terms of speed of cooling, outline induction hardening,

Q3 Heat treatment & Iron Carbon

• 2006• Select two temp zones on the dwg & explain

the treatment processes they represent,• Compare – ferrite & martensite, upper and

lower critical temp, stainless steel & high speed steel, eutectic & eutectoid point

• Optical pyrometer – id & state its function and how it works,

Q5 Welding

• 2012• Describe S.A.W. & where used• Describe Colour coding oxyacetylene equip – 3

safety precautions preparation equip & materials

• Describe multi run welds• Describe auto welding of car panels,• Describe main features of TIG & MMA

Q5 Welding

• 2011• Describe MMA – identify & state function of

the MMA circuit,• How minimise electrical hazards in MMA – 3

ways to prevent atmospheric contamination – why TIG for Aluminium – Function of Dissolved acetylene,

• Describe Seam welding & SAW

Q5 Welding

• 2010• Name TIG & MIG – name application for each

and how they work,• State (oxyacetylene equip) – 3 safety

precautions integrated into the equip – 2 functions of slag in MMA – Use for SAW, Describe resistance welding

• Describe Electro-slag welding & oxyacetylene• Or outline why robots for spray painting –

testing pipes or placing electronic parts,

Q5 Welding

• 2009• Id Seam & spot welding, describe how they work• Distinguish MIG & TIG - state 2 functions of

electrode coating in MMA – 2 factors when installing a welding station in school – describe multi run welds,

• Describe transformer circuit in MMA, S.A.W.• Or advantage using air to power robots for

assembly – benefits using robotic control for hazardous environments

Q5 Welding

• 2008• Describe TIG using name, how it works, uses• Oxyacetylene – 2 safety features in the equip,

explain two parts of the gauges, whats dissolved acetylene, difference oxydising & carburising flames

• Describe main features of spot welding & MIG• Or 2 industrial uses where robots are used,

advantages of stepper motors in robots

Q5 Welding

• 2007• SAW – Describe how it works and where used• Redraw incomplete transformer circuit,

describe function of a & b, advantages multi run welds, 3 safety precautions preparing materials for welding

• Describe seam welding & electro slag welding• Or 2 safety factors setting up robotic welding

facility,

Q5 Welding

• 2006• MIG welding, name it , how it works, where its

used,• MMA – 2 functions of electrode, 2 important

functions of the slag, explain bridge rectifier, know 3 safety hazards and remedy for each,

• Describe spot welding & TIG• Or benefits robots in car assembly, what is

‘working envelope’

Q6 Polymers

• 2012• Describe compression moulding, polymer

used, and a component• Distinguish thermo & thermosetting using

polymerisation process, bonding, structure, properties

• Explain – elastomer, catalyst, blow moulding, G.R.P. Laminate

Q6 Polymers

• 2011• Describe Addition polymerisation, name a

material,• Describe extrusion, state polymer, name

component• Explain – Plasticiser, Filler, Lubricant, stabiliser,

pigment

Q6 Polymers

• 2010• Identify calarindering and describe how it works

– name one part produced• Distinguish thermo & thermosetting using

bonding, structure, properties (same as 2012)• Explain – stabiliser, glass transition temp,

condensation polymerisation, elastomer, elastic memory in perspex

Q6 Polymers

• 2009• Id Calandering & extrusion, id one component,

describe how they work,• Describe polymerisation for polyethylene• Explain, Blow moulding, Elastomer, Catalyst,

Co –polymer, Thermosetting plastic,

Q6 Polymers

• 2008• Extrusion–id function of 3 part, id a component• Distinguish thermo & thermosetting using

polymerisation process, bonding, properties (2012)• Explain Transfer moulding, GRP, Cross linking,

Laminate, Polymer filled materials

Q6 Polymers

• 2007• Id & describe how transfer moulding works , name

1 component,• State function of pigments, plasticisers, lubricants• Explain condensation polymerisation, extrusion,

elastomers, van der walls forces, monomer,

Q6 Polymers

• 2006• Distinguish thermo & thermosetting using

polymerisation process, bonding, internal structure, properties, (2008)

• State function of fillers, stabilisers, catalyst, foaming agent

• Describe injection moulding process, how it works, one part produced, name some parts.

Q8 mechanisms

• 2012• Describe ball bearings, vee belt pulleys• Explain – idler gear, car batteries, ratchet &

pawl mechanism, heat sink in electronics, advantages of solar panels,

• Describe method of independent drive to each wheel of moon buggy

• Or electronics question

Q8 mechanisms

• 2011• Describe bevel gears & roller bearings• Explain vee pulleys, chain & sprocket, toggle,

LDR, function electronic transistor,• Describe mechanism to control steering of go-

kart,• Or electronics question

Q8 mechanisms

• 2010• Identify Universal joint & cam shaft and cams• Explain bevel gears, double acting cylinder,

clutch, idler gear, capacitor,• Describe mechanism to control up & down

dentists chair,• Or electronics – id circuit diagram

Q8 mechanisms

• 2009• Id socket set ratchet & timing belt, suggest use• Explain helical gears, preventing slip in pulley

belt system, crank & slider, integrated circuit, solenoid,

• Describe mechanism to rotate jewellery box• Or id & describe function of the electronic

components

Q8 mechanisms

• 2008• Id and use for bevel gears & ball bearing• Explain electrical relay, clutch, shuttle valve,

rack & pinion, capacitor,• Describe a mechanism to lift heavy loads• or id & describe function of the electronic

components

Q8 mechanisms

• 2007• Id rack & pinion & worm gears, state where

used• Explain Idler gears, Universal joint, solenoid,

pneumatic flow regulator, solar panel,• Describe mechanism to automatically open a

door• Or id & describe function of the electronic

components

Q8 mechanisms

• 2006• Id Timing toothed belt & cam and follower and

give an application,• Explain compound gear train, advantage gears

over pulleys, outline function of idler gear, outline between bevel and worm gears, describe 2 uses of rack and pinion mechanism

• Describe the operation of a power hacksaw• Or id & describe function of the electronic

components,