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GCSE
ENGINEERING
Unit 1 Written Paper

Time allowed: 2 hours

Materials
For Examiner’s Use
For this paper you must have:
• normal writing and drawing instruments Question Mark
• a calculator.
1

Instructions 2
• Use black ink or black ball-point pen. Use pencil only for drawing. 3
• Fill in the boxes at the top of this page. 4
• Answer all questions.
5
• You must answer the questions in the spaces provided. Do not write
outside the box around each page or on blank pages. 6
• If you need extra space for your answer(s), use the lined pages at the end of 7
this book. Write the question number against your answer(s).
8
• Some questions will require you to shade a circle. If you make a mistake
cross through the incorrect answer. 9
• Do all rough work in this book. Cross through any work you do not want to be TOTAL
marked.

Information
• The marks for questions are shown in brackets.
• The maximum mark for this paper is 120.
• You are reminded of the need for good English and clear presentation in your answers.

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Answer all questions in the spaces provided. box

For each question completely fill in the circle alongside the appropriate answer.

CORRECT METHOD WRONG METHODS

If you want to change your answer you must cross out your original answer as shown.

If you wish to return to an answer previously crossed out, ring the answer you now wish to select
as shown.

0 1 . 1 Which of the following describes an alloy?

[1 mark]

A A liquid metal

B A mixture including metallic materials

C A mixture of non-metallic materials

D A pure metal

0 1 . 2 Which heat treatment process for steel involves heating to high temperatures then
cooling rapidly in water?
[1 mark]

A Annealing

B Galvanising

C Hardening

D Normalising

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0 1 . 3 Which of the following is a thermosetting polymer? box

[1 mark]

A Acrylic

B Nylon

C Polypropylene

D Polyurethane

0 1 . 4 Which of the following is a pushing force that moves an object forwards through
the air?
[1 mark]

A Drag

B Friction

C Lift

D Thrust

0 1 . 5 Which one of the following properties allows a material to resist bending?

[1 mark]

A Brittleness

B Hardness

C Stiffness

D Toughness

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0 1 . 6 Which of the following is an output component? box

[1 mark]

A Light dependent resistor

B Light emitting diode

C Thermistor

D Timer

0 1 . 7 Name the component shown in Figure 1.

[1 mark]

Figure 1

A Capacitor

B Microcontroller

C 7 Segment Display

D Transistor

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0 1 . 8 Complete the following statements using the word bank provided. box

Composites are materials made by two or more

different materials.

They can have that are not possible with individual

materials.

A disadvantage of composites is that they are difficult to separate and cannot be

easily .

Word bank

colours, combining, joined, layering, properties, recycled, shaping, substituted,

textures
[3 marks] 10

Turn over for the next question

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0 2 . 1 Stainless steel pans are shown in Figure 2. box

Figure 2

Give three reasons why stainless steel is a suitable material for the pans.
[3 marks]

Reason 1

Reason 2

Reason 3

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0 2 . 2 Use notes and sketches to explain how two metal parts can be fastened together box

using riveting.
[4 marks]

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0 2 . 3 A drilling machine is shown in Figure 3. box

Figure 3

Evaluate two risks of using this machine.

[4 marks]

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0 2 . 4 Inside the drilling machine there is a simple gear train. box

The driver gear has 85 teeth and the driven gear has 152 teeth.

Calculate the gear ratio.

Show your working.

Give your answer to two decimal places.

[3 marks]

Answer

0 2 . 5 The speed of the drilling machine motor is 1430 rpm.

Calculate the output speed.

Show your working.

Formula:
Speed driver gear Number of teeth on driven gear
=
Speed driven gear Number of teeth on driver gear
[2 marks]

Answer rpm

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0 2 . 6 Identify one difference between drilling using a pillar drill and drilling using a lathe. box

[2 marks]

0 2 . 7 Figure 4 shows a block of material.

Figure 4

Name the machining processes used to create the flat surface shown at A and the
groove shown at B.
[2 marks]

Flat surface A process

Groove B process 20

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0 3 Two bridges made from different materials are shown in Figure 5 and Figure 6. box

Figure 5 Figure 6

Structural concrete Structural timber

Analyse the suitability of the two materials for constructing a bridge in terms of the
following:
[6 marks]

Properties

Advantages

Disadvantages

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0 4 . 1 Figure 7 shows a greenhouse manufactured using standard forms of material. box

Figure 7

The manufacturer is considering offering different sizes of greenhouse.

Analyse the manufacturing and cost implications of using standard forms compared to
specially made.
[4 marks]

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0 4 . 2 Table 1 shows material costs for a greenhouse. box

Table 1

Material Cost Quantity

Aluminium frame £1.72 per m 47

Polycarbonate panels £3.06 per panel 32

Fastenings £7.75 per pack 1

The greenhouse requires 1.5 hours of manufacturing time at £30 per hour.

Calculate the total cost of manufacturing the greenhouse.

Show your working.

[4 marks]

Answer £

0 4 . 3 The manufacturer estimates that the total cost of the greenhouse would be 37%
higher if made from toughened glass panels.

Calculate the total cost of the greenhouse if toughened glass panels were used.

Show your working.

[2 marks]

Answer £

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0 4 . 4 Other than cost, evaluate which other factors engineers need to consider when box

selecting materials.

Give examples in your answer.

[6 marks]

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0 4 . 5 Name a suitable production process for shaping polystyrene. box

Explain why that process is suitable.

[3 marks]

Process

Explanation

0 4 . 6 Explain the advantages of Fibre Reinforced Polymers (FRP).

[2 marks]

21

Turn over for the next question

Turn over ►

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0 5 A lathe is shown in Figure 8. box

Figure 8

0 5 . 1 Identify the parts of the lathe at A and B.

[2 marks]

Part A

Part B

0 5 . 2 Figure 9 shows a tool used on the lathe.

Figure 9

Name the tool in Figure 9 and explain what it is used for.

[2 marks]

Tool name

Used for

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0 5 . 3 A metal part will be taper turned. box

Calculate the angle of the taper shown as 𝜽𝜽 on Figure 10.

Show your working.

[3 marks]

Figure 10

Answer degrees

Question 5 continues on the next page

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0 5 . 4 An aluminium coat hook is shown in Figure 11. box

Figure 11

Complete the table to create a production plan to manufacture the coat hook.

Some parts have been completed for you.

[6 marks]

Order Process Hand tools Description of process

Mark out the size of the coat

Mark out the coat hook and the position of the
1 Scriber, steel rule
hook shape. holes with a steel ruler and a
scriber.

2 Cut out the shape.

Centre punch the position of the

3 Make the holes. Centre punch, drill holes. Clamp the work piece
and drill through the material.

Refine the edges and

4
holes.

5 Bend to correct angle.

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0 5 . 5 A fixing hole in the coat hook is changed to the shape shown in Figure 12. box

Figure 12

Name two machining processes that could be used to cut out the fixing hole shape.
[2 marks]

Process 1

Process 2 15

Turn over for the next question

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0 6 . 1 A sine wave is shown in Figure 13. box

Figure 13

Does the sine wave represent an analogue or digital signal?

[1 mark]

0 6 . 2 Name one benefit of using a piezo sounder rather than a buzzer in a circuit.
[1 mark]

0 6 . 3 Describe how an engineer would predict performance in an electronic circuit.

[2 marks]

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0 6 . 4 A circuit for a light emitting diode (LED) contains a 250 Ω resistor and the voltage box

is 6 V.

Calculate the current flowing through the circuit.

Use the formula V = I × R

Give your answer to three decimal places.

[4 marks]

Answer with unit

0 6 . 5 Explain why a resistor is required in the LED circuit.

[2 marks]

0 6 . 6 Give one example of when an Analogue to Digital Conversion (ADC) is used.

[2 marks]

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0 6 . 7 A system is designed to operate a motorised window blind. box

The system consists of a motor, light sensor, a microcontroller and a Field Effect
Transistor (FET).

In the space below, draw a systems diagram to show the operation of the motorised
window blind.
[6 marks]

0 6 . 8 Analyse the use of a motorised window blind system rather than a manually
operated one.
[2 marks]

20

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0 7 . 1 Name one non-renewable form of energy production. box

[1 mark]

0 7 . 2 Tidal energy and wind energy are two methods of renewable energy production.

Compare the use of the two energy methods.

Discuss the following aspects in your answer:

• advantages and disadvantages

• impact on the environment.
[8 marks]

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0 8 . 1 Figure 14 shows a brake lever and cable. box

Figure 14

The inner cable has a diameter of 1.6 mm. The force applied by the lever is 70 N.

Calculate the stress applied to the inner cable when the lever is pulled.

Formula: Stress = Force/Cross section area

Cross section area = πr2

[3 marks]

Answer N/mm2

0 8 . 2 State which force is applied to the inner cable when the brake lever is pulled.
[1 mark]

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0 8 . 3 The manufacturer must test the inner cable to determine how much it stretches. box

Using notes and sketches, design a test that would assess this property of the
inner cable.
[6 marks]

Question 8 continues on the next page

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0 8 . 4 Table 2 shows the results of testing when increasing force is applied to the box

inner cable.

Table 2

Force in N 20 40 60 80 100 120

Length in mm 1650 1652 1655 1659 1664 1670

Using the data in Table 2, plot a graph to show the relationship between the force
applied and the change in length.

Marks will be awarded for:

• labelling the axes

• plotting the data onto the graph
• drawing a line to connect the plotted data.
[4 marks]

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0 8 . 5 Predict the length of the inner cable if a force of 110 N is applied. box

[1 mark]

Answer mm

0 8 . 6 State the material property that allows the inner cable to stretch when a force
is applied.
[1 mark]

16

0 9 . 1 Name one example of a rapid prototyping process.

[1 mark]

0 9 . 2 Give two advantages of using a rapid prototyping process.

[2 marks]

Advantage 1

Advantage 2
3

END OF QUESTIONS

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Question Additional page, if required.
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Question Additional page, if required.
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