Question 1: Explain two key differences between ferrous and non-ferrous metals in terms of their properties and common applications.

Answer: Ferrous metals contain iron and are magnetic, generally more prone to rusting (e.g., steel, cast iron). Non-ferrous metals do not contain iron, are non-magnetic, and more resistant to corrosion (e.g., aluminium, copper).

Question 2: Identify a suitable metal for manufacturing a lightweight bicycle frame and justify your choice based on its properties.

Answer: Aluminium is suitable because it is lightweight, corrosion-resistant, and has good strength-to-weight ratio, making it ideal for bicycle frames.

Question 3: Describe the process of annealing and explain how it alters the properties of a metal.

Answer: Annealing involves heating a metal to a specific temperature and then slowly cooling it. This process softens the metal, relieves internal stresses, and improves ductility, making it easier to work with.

Question 4: Sketch a detailed cross-section of a typical steel alloy used in construction, labeling key components such as carbon content and any alloying elements.

Answer: A cross-section showing a steel matrix with annotations indicating the presence of carbon (e.g., 0.2-2%) and alloying elements like manganese, chromium, or nickel, depending on the specific alloy.

Question 5: Design Brief: You need to create a decorative yet sturdy door handle using metal. Which metal would you choose and why? Include at least two reasons in your answer.

Answer: I would choose brass because it has an attractive appearance, good corrosion resistance, and is easy to shape and polish, making it suitable for decorative handles.

Question 6: Sketch a simple plan for a metal bracket intended to support a shelf in a kitchen. The plan should include dimensions and fixing points.

Answer: A rectangular bracket with two mounting holes on each side, a horizontal support arm, dimensions approximately 150mm long, 50mm wide, with holes spaced evenly for wall screws.

Question 7: List three environmental considerations that should be taken into account when selecting a metal for outdoor use.

Answer: Corrosion resistance, durability against weather conditions, and the environmental impact of mining and processing the metal.

Question 8: Explain why stainless steel is often used in kitchen appliances and cutlery.

Answer: Stainless steel is corrosion-resistant, durable, easy to clean, and maintains a polished appearance, making it ideal for kitchen environments.

Question 9: Describe the differences between casting and forging as methods of shaping metals. Mention one advantage of each method.

Answer: Casting involves pouring molten metal into a mold to create complex shapes, offering design flexibility. Forging involves shaping metal through hammering or pressing, which improves strength and grain structure.

Question 10: Create a labelled sketch of a simple metal fastener such as a rivet or screw, indicating the main components and their functions.

Answer: A fastener sketch showing the head, shank, and threaded section, with labels indicating the head for turning, the shank for insertion, and the threads for gripping materials.