KCSE Past Papers Metalwork 2011

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4.5 METAL WORK (445)

4.5.1 Wood Work Paper 1 (445/1)

SECTION A (40 marks)

Answer all the questions in this section.

1 (a) State four causes of accidents when using a cold chisel. (2 marks)

(b) State the minimum entry requirement for each of the following courses:

(i) artisan;

(ii) diploma;

(iii) craft. (1 1/2 marks)

2 (a) Outline the procedure of reading a micrometer. (2 marks)

(b) State four uses of a scribing block. (2 marks)

3 (a) Use sketches to show the length of each of the following rivets:

(i) countersunk head;

(ii) round head;

(iii) raised countersunk. (3 marks)

(b) Use labelled sketches to show two uses of a template. (3 marks)

4 Name a suitable material and state the property that makes it appropriate for making each of the following:

(a) twist drill bit;

(b) rivet;

(c) head of ball pein hammer;

(d) kitchen knife blade. (4 marks)

5 (a) With reference to filing explain:

(i) the term pinning;

(ii) how pinning is prevented;

(iii) how pinning is treated. (3 marks)

(b) (i) Use a labelled sketch to show the safe edge of a file.

(ii) State the function of the safe edge of a file. (2 marks)

6 (a) State two advantages of a leg vice over engineer’s vice. (2 marks)

(b) Outline the procedure of locating the centre of a round bar using the centre head and the rule of a combination set. (2 marks)

7 (a) State two forms in which filler metal for brazing is manufactured. (1 mark)

(b) Give one reason for manufacturing filler metals in different forms. (1 mark)

8 (a) Explain the term welding. (1 mark)

(b) State two advantages of rightward welding over leftward welding. (2 marks)

9 Describe the process of oil blanking as applied to metal finishing. (3 marks)

10 Figure 1 shows an oblique drawing of a block.

Sketch in third angle projection the three orthographic views of the block. ( 5 1/2 marks)

SECTION B (60 marks)

Answer question 11 and any other three questions from this section.

Candidates are advised to spend not more than 25 minutes on question 11.

11 Figure 2 shows orthographic views of a machined block drawn in third angle projection.

On the grid paper provided, draw the isometric view of the block taking X as the lowest point.

Show three leading dimensions. (15 marks)

12 (a) Figure 3 shows a link to be made of 6 mm thick mild steel. Outline the procedure of making the link naming all the tools required in each step. (6 marks)

(b) (i) Sketch a pop rivet and label its parts.

(ii) List three steps involved in preparing work pieces for pop riveting.

(iii) With the aid of sketches, outline the procedure of pop riveting. (9 marks)

13 (a) Sketch an anvil and label three parts. (3 marks)

(b) Figure 4 shows a portion of an arm bar made from a 6.0 mm square mild steel rod.

(i) Determine the length of the material required to form the bend labelled l.

(ii) With the aid of sketches, outline the procedure of making the arm bar. (11 1/2 marks)

14 (a) Use sketches to show the difference between a lap joint and a flush lap joint. (2 marks)

(b) Outline the procedure of sweating as applied to soft soldering and name all the tools and materials required in each step. (8 marks)

(c) Give four safety precautions to be observed when soldering. (2 marks)

(d) State three reasons why copper is preferred in making head of a soldering iron. (3 marks)

15 (a) Sketch a gas welding torch and:

(i) label five parts;

(ii) state three precautions to be observed when handling it. (7 1/2 marks)

(b) (i) Use labelled sketches to show the three types of gas welding flames.

(ii) Explain how each of the flames is obtained. (7 1/2 marks)

22.0 METAL WORK (445)

22.1 Metal Work Paper 1 (445/1)


Failure to hold chisel firmly

Failure to use goggles

Using chisel with mushroomed head

Using blunt chisel

Failure to hold work piece firmly

Grieared chisel .

Any 4 x 1/2= 2 marks



(ii) DIPLOMA KCSE (C Plain) or Craft certificate

(iii) CRAFT KCSE (D Plain) of Artisan


Read the whole number on barrel/ sleeve

Read complete subdivision on barrel

Read number on thimble before datum line

Read extra

divisions coinciding with datum line

Finding the centre of the round bar.


Marking out

Testing parallelism

Testing alignment

Testing roundness/concentricity 4 X 1/2= 2 marks

3. (a)


(b) Marking + appropriate sketch

Checking + sketch

Guiding + sketch All) 3 X 1= 2 marks

4. (a) Twist drill I-ISS/HCS Hardness and wear resistance (b) Rivet MS, Alminium, Brass, Copper Malleability/ductility 477 3x % =17; marks‘ 4 x y2= 2 marks 3x l=3 marks ;? ¢ ‘;\r z 2: a i. ‘i 3?" = l l mm tealmlnz fig ;€I‘nny nnchl-Qgbéonn (C) (<1) 5. (a) (b) 6. (a) (b) 7‘ (a) (b) 8. (a) (b) Hammer head Medium Carbon Steel Toughness/hardness Knife blade Stainless steel Non-corrosive/hardness/easy to cold work 8 x y2= 4 marks (i) Clogging of a file by metal chips (ii) Applying chalk on the surface (m) Cleaning using a file card or wire brush 3 x 1= 3 marks in sm um "2 Marks Kllmvs filing one surface of a shoulder or inner corner lg mark l Allows filing one surface of a shoulder or inner corner yz 2 marks LEG VICE Enhanced rigidity hence withstands heavy blows Capable of opening more hence holds Wider work piece Withstands very high temperatures Any 2 x l= 2 marks Slide the rule through the slot in the centre head and lock. Hold the centre head against the end of the bar Scribe a line across the end of the bar Rotate the bar and scn'be another line to obtain a centre of intersection/bar 4 x }§= 2 marks Forms: Rod, wire, strip, powder Any 2 x %= l mark REASON: T0 cater for - thickness of material being brazed - the design of the joint - method of heating the metal Any 1 x l= 1 mark WELDING The process of joining metals by heating them to melt and fusing together. RIGHTWARD WELDING Deeper penetration and faster Rate of cooling is reduced hence better results Less gas is used No berel is required for steels up to 8.0 mm thus less filler metal required/used.. Any 2 x1= 2 marks 478 tofu zsepwma zar=-'2.~§m€a=¢; Q www.xmnny-Inli-.ncl11IQ-conn /' 9. OIL BLACKING Clean the surface Heat to red hot Dip in clean thick oil Heat again to Allow to cool bum excess oil Clean the surface 10. ll. 12. (a) (i) <9? (111) (lv) (v) <19 (v11) (vm) (iX) SOLUTIDN §0LUTlUH 9 faces a,§ , Hi Hidden details = Q 3'dAngle projection = )5 TOTAL = $15 marks Scribe the centre line using a scriber Step off the 75mm hole centres using dividers Dot punch hole centres using hammer and punch Scribe 18mm radius using dividers and rule Scribe 25mm radius using rule and dividers Join 18mm and 25mm radii tangentially using rule and scriber Drills holes Q 18 and Q 25 using a drill bit. Cut along the outline using a hacksaw File the outline smooth using a file. 479 6 x }§= 3 marks 6 x l= 6 marks www nanny-Inli-much!-Q coin Erjfu §@€@§'m° Ear-‘1~§m@=@§ g \\. (b) (i) POP-RIVET H h c a :3 »-_» ta old y k\\\\* $\x\\: ‘U 1? Sketch and labelling = 211 marks (ii) STEPS Mark and drill the plates Debur the plates Align the holes 3x V2: 1% marks (m)I nsert the rivets into the work piece and grip the pin with the rivet gun. Press the gun to pull the pin causing the head to expand the body. Continue pressing the gun until the pin breaks off. 3 x l= 3 marks Any 2 sketches X 1= 2 marks 13. (21) ANVIL MQVH. Fanning ale S’ ' Huufio kale F Ta an '“' ""' sum» = 2 Label1ing(3x 1: 1* TOT“ = 31h marks Hod.’ "l==I=====-wnnnnnn \ Q! , (b) (i) LENGTH OF MATERIAL Inner radius 18 Outer radius 18 + 918 + 3)y, Mean radius Q = 21 2 Length of curvature = 1 4 X /Z = 2 marks 4 = (2 X L X 21) X g 7 = 33mm (ii) RADIUSED BEND Obtain a suitable template/jig for Q 36 or R18 Mark the area to be bent Heat the area to be bent Clamp Work piece against the jig Bend to shape. 5 x % = 2 7; marks 480 ? z \=\7 1 2: as <1. '1 37' = l W mnugwmnnn _;fl1F'tc> ¢,,,.,, r .¢ i Auiymn um gas IIIII1>0xyq1n|and full gas mixture Skiith = 2 Labelling mat = ii SAFETY PRECAUTIONS - Ensure that the nozzle seat and threads are free from any foreign materials. 482 ? 1 \;\7 § 2: 5 i. '1 37' = mnupmnnu _;1]IF'tc>alm1n:Ib: 11% v\*ww.xz1nny-.nnli-nncl1lIQ-con1 - Nozzle should only be cleaned with tip cleaner - Never use nozzle to hold or push the Work piece - Avoid knocking nozzle against hard surfaces Any 3 x l= 3 marks AS WELDING FLAMES "5181?! defined inner cane % N L The neutral flame (b) G (i) 3 " li = 4-imarks Feather ~T?*w?>&\ e + "‘\~_>_-__...- ———>{ U} i-__ The carburisinq flame I *1 :,\;;' " "‘??TI‘?f~m (ii) 1. Neutral Flame has equal quantities of oxygen and acetylene ' ' flame has more acetylene gas than oxygen as Carbunslng x gen than acetylene g 3 x 1 2. 3. Oxiding flame has more 0 y 483 W '= 2* °m»§m;§_;z§ Q J‘ N 1 F , i £€I'nny.nnfinnchl-Q-co

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