Engineering Manufacture OCR R109 Practice Test

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• Which process forces heated plastic granules into a mould cavity to form products?
• In terms of automation, which outcome is listed as an impact on output?
• Which process uses heated moulds to press a thermosetting plastic together under high hydraulic pressure?
• What is the process called when a thin layer of zinc is applied to iron or steel to protect against rusting and mechanical damage?
• Which process uses a punch and a die to press metals into shape?
• Which metal type contains iron, is silvery-grey, prone to rust and corrosion, and is magnetic (except stainless steel)?
• Which statement about water jet cutting is true?
• What is the next step after the mould is heated in the investment casting process?
• Refractory inorganic nonmetallic material baked from clay and minerals at high temperatures describes which category?
• Which material is lightweight, malleable, ductile, with good corrosion resistance and conductivity, low density; used for aircraft bodies, drinks cans, cooking foil, and window frames?
• What is the primary purpose of destructive testing?
• What is the term for a mixture of two or more metallic elements which gives enhanced properties?
• Which process rubs a material with fine abrasives to produce a smooth, shiny and glossy finish?
• Which coating minimizes slippage and provides wear resistance?
• Which polymer is commonly used for ropes, packaging and films because of its low density and flexibility?
• Rockwell hardness testing uses an indenter to apply a minor load and then a larger load; the hardness value is obtained from what?
• Which technique uses mechanical fasteners rather than heat or adhesives to join pieces?
• Which property describes the ability to return to original shape after removing deforming forces?
• Which term describes processes such as linishing, polishing, plastic/powder coating, painting, electroplating, and galvanising to achieve surface appearance and properties?
• Which characteristic concerns the ease with which materials can be used in design and manufacture?
• Which process involves a mould containing heated thermoplastic powder that is rotated while heat is applied to form a hollow product?
• Which is a characteristic related to how easily engineering materials can be acquired?
• Which machine is used for punching and embossing flat sheet materials for aesthetics or to produce structural form features and extending static stability?
• Which process uses laser to sinter polymer powders?
• Which term refers to surface treatments intended to improve appearance and functional properties without changing core material?
• Which heat-treatment process hardens the surface of a metal while leaving the inside softer and tougher?
• During the investment casting process, what is the purpose of dipping the wax pattern into a refractory slurry?
• Which operation is described as abrasive cutting in which a toothed saw blade removes a kerf of material?
• Which operation involves particles rubbed off when smoothing or shaping with a file?
• Which joining method uses melting solder to join metal pieces?
• Which advantage supports development in poorer countries?
• Which disadvantage concerns skill bases in other countries?
• Which polymer is light, strong and used for vacuum forming in schools and packaging?
• Which advantage concerns market accessibility?
• Practically the same as SLS but uses metal powder.
• What is the general term for a material that combines two or more different materials to achieve better properties?
• Which polymer is low density, tough, flexible and used for ropes, carpets and packaging?
• What are materials that change color in response to temperature called?
• Which process describes heating metal to a high temperature, introducing carburising powder, soaking, reheating, and quenching to harden the surface?
• Which material is commonly used for cutting tool tips due to its hardness and high melting point?
• Which technique uses a moving belt to abrade and smooth a surface before finishing?
• Which polymer is strong, elastic, tough, lightweight, colourfast, durable and used for clothing, carpets and upholstery?
• Which of the following is listed as an advantage of global manufacturing?
• Fatigue testing measures how many cycles to failure under repeated loading. What does this test quantify?
• What term describes the controlled heating and cooling of metals to alter their properties, including hardening, tempering, case hardening, annealing, normalising and nitriding?
• Punching machines are commonly used to create which feature on flat sheet materials?
• Which metal is described as shiny, soft, malleable, ductile and strong and used to make steels and girders?
• Which resin, used to form glass reinforced plastic (GRP), is stiff and an insulator?
• Which polymer is described as tough, corrosion resistant and used for toys, protective headgear and canoes?
• Similar to annealing but it cools at room temperature environment after being heated so it remains a little more hard and a little less ductile; it is a form of annealing used only on steels and is cheaper due to reduced furnace time. Which is this?
• Which material becomes conductive when squeezed and is used in membrane switches and pressure sensors?
• Which metal is ductile, malleable, an excellent conductor, reddish-brown, and corrosion resistant, used for pipes, wire, and cookware?
• Which term refers to the group of manufacturing operations that include drilling, turning, milling, and grinding?
• Which item is a category of fasteners that include screws, nuts and bolts and have threads?
• Which material is lightweight with low density and used for aircraft bodies and beverage cans?
• Which coating uses finely ground pigment or resin particles that are electrostatically charged and sprayed onto a surface to resist wear?
• What cutting process uses a high-speed and high-pressure jet of water to cut materials such as textiles, wood and stone, leaving no burrs and no heat?
• Compared with CNC milling machines, CNC routers typically:
• Which casting method uses a wax pattern, a refractory slurry around it, dewaxing, pouring metal, and destroying the shell to release the part?
• Which material is used when high hardness is needed for tools such as screwdrivers and hammers?
• Which category includes sawing, filing, and threading?
• Which material is an alloy of copper and tin commonly used for statues, coins, bearings, and underwater fittings?
• Which term means a combination of two or more metals to enhance properties?
• Which material is hard, strong, stiff, and an insulator, and is used for plug sockets and door handles?
• Which material is an alloy of lead and tin with a low melting point, used for plumbing and joining electronic components?
• Which category includes a refractory inorganic nonmetallic material baked from clay at high temperatures?
• Which material is heat resistant, transparent, and corrosion resistant, used for jars, glasses, and window panes?
• Which polymer is used for eyewear and protective glass due to its strength and clarity?
• Which screw is capable of tapping its own hole when driven into material?
• Which metal is soft, dense, malleable and tarnishes, used in batteries and x-ray shielding?
• Punching machines are commonly used to create what on flat sheet materials?
• Which material is silicon nitride with low conductivity and high heat resistance?
• Which surface hardening method uses nitrogen by heating with ammonia?
• Which material is strong, lightweight, and an insulator, used for water tanks, surfboards, and boats?
• A cutting tool moves in linear directions to remove material from a spinning workpiece. Which process is described?
• Which process cures a liquid resin with a guided laser beam?
• The ability to be stretched and drawn under stress into a wire is the definition of which property?
• An electron beam targets and melts together layers of powder.
• HDPE is strong and stiff and used for pipes and buckets. Which term describes this material?
• What is an impact of digital communications on global manufacturing?
• Which characteristic addresses the environmental impact over the lifecycle of the material?
• Which material, similar in function to shape memory alloys, can be used for selectively pliable tools?
• Which operation bends metal to a desired shape by applying force?
• What capability does a multi-axis machining centre provide that allows multiple operations without changing machines?
• Which characteristic describes non-destructive testing?
• Melted polymer is applied by a moving nozzle layer by layer, commonly known as 3D printing.
• Which process heats a thermoplastic until soft and then bends it at any chosen angle?
• Which process uses a thermoplastic sheet formed by heating and drawing onto a mould with vacuum to yield shallow parts?
• Polymers that cannot be remelted because they have cross-links between chains are known as:
• Which feature relates to safety during use of engineering materials?
• Which process involves heating a steel and quenching it with water or oil to achieve a suitable hardness and toughness ratio?
• Which material is hard, abrasion resistant with a high melting point, used for cutting tool tips and jewellery?
• The ability to deform and be hammered into shape under stress without breaking relates to which property?
• Which bonding method uses a sticky adhesive such as epoxy or glue to hold materials together?
• Which process uses an abrasive spinning grinding wheel to remove material or smooth it?
• Which polymer is stiff, hard-wearing and used for pipes, electrical cable jackets, packaging?
• What term describes materials that change in properties in response to stimuli?
• Which advantage relates to standardised processes?
• Which disadvantage relates to employment in the parent country?
• What term describes metals that can return to their original shape after deformation when heated?
• Which rapid prototyping process fabricates a part layer-wise by hardening a resin with a guided laser beam?
• Which advantage relates to workforce and expertise?
• In Brinell hardness testing, what type of indenter is used and how is hardness determined?
• Which polymer is strong, stiff, hard, tough, transparent and heat and impact resistant, used for eyewear and bullet-proof glass?
• Which statement is NOT listed as an impact on quality due to automation?
• Forcing molten metal under high pressure into a mould cavity describes which casting process?
• Which operation uses a tap-wrench to cut screw threads?
• Which process uses a filler metal that melts at a lower temperature to join metal pieces?
• What process involves pouring liquid metal into a mould to solidify?
• Which material is used for household glassware such as jars and window panes and is known for transparency and heat resistance?
• Low-density polyethylene is flexible, soft, tough and used for plastic bags. Which term is this?
• Which advantage involves information flow across borders?
• Direct metal laser sintering (DMLS) is practically the same as SLS but uses metal powder.
• Which material is ductile, malleable, prone to rusting and used to make car bodies, girders, gates?
• Which metal is hard, brittle, and very corrosion resistant, consisting of copper and tin, used for statues, coins, bearings, and underwater fittings?
• Which material is strong, stiff, lightweight and a conductor, commonly used for aircraft, racecars, and bicycle frames?
• A process where a rotary cutter removes material by advancing onto a workpiece is called?
• Which material is molten impure iron from a blast furnace used for moulds, with good compressive strength but brittle, and used for brake discs, machine bases, vices, manhole covers, and engine blocks?
• For maintaining a sharp cutting edge, which property is most important?
• Which item is an advantage related to distribution and markets?
• Creep testing evaluates deformation under sustained stress at elevated temperature over time. What does it simulate?
• Which material is strong and durable and used for buildings, bridges, roads, dams, and kerbs?
• Which metal is resistant to corrosion but weak by itself, so it is used for galvanising to make other materials corrosion resistant?
• In shell moulding, what happens to the core after cooling?
• Which process involves heating a metal and letting it cool slowly at a controlled rate in a furnace aiming to rearrange the internal crystal structure of a metal to make it less hard and more ductile?
• Rotating tools rapidly remove material, which is attached to a moving stage and is computer controlled. Which machine is described?
• Which factor refers to the ability to supply the material in different forms or quantities?
• Which term best describes deforming an object by forming metal through hand methods (stretching and shrinking)?
• Which term refers to the process of hardening a steel and then tempering to adjust toughness?
• Which technique joins metal pieces using rivets driven through aligned holes?
• Which rapid prototyping process uses a moving laser beam to sinter heat-fusible powders one layer at a time?
• Dipping ferrous metals into a chemical coating to make them corrosion resistant is known as what?
• The maximum stress that a material can withstand while being pulled before failure is termed what?
• Which process forms hollow metal parts using resin-coated sand in a mould with two heated halves?
• Which is a digital communications use in research and development?
• Which process includes case hardening and nitriding as examples?
• What term describes a material's resistance to chemical attack?
• What manufacturing process pushes material through a die to achieve a desired cross-section, and can use plastic or metal, hot or cold?
• Which is a disadvantage related to facility concentration?
• Which of the following is not listed as a welding type?
• Polymers that can be softened by heating are called:
• Which material is resistant to wear but brittle and is commonly used for drill bits and lathe cutting tools?
• Which statement is true about video conferencing in this context?
• The ability to withstand a force that squeezes it is called which property?
• Which process uses air blown into an extruded tube with moulds on either side closing to form hollow products?
• A spindle with a material attached rotates as a CAD program controls a multi head tool changer to remove material. Which machine is this describing?
• Which advantage helps economies adjust to changes in country conditions?
• What is the process called when electricity is used to coat a thin layer of metal onto an object for decoration and to stop rusting and corrosion?
• Which polymer's abbreviation stands for Polyvinyl Chloride?
• The ability to withstand a force that pulls it is known as which property?
• Which property describes permanent deformation after removal of a force?
• Which metal category does not contain iron?
• Which process uses an electron beam to melt powder?
• Involves use of a laser to melt the bond line between two parts to form a weld. Which welding method is this?
• In investment casting, a wax pattern assembly is usually attached to what central structural element?
• What happens after the wax is removed from the refractory mould in investment casting?
• Which process deposits melted polymer via a moving nozzle?
• Which process fuses two pieces of metal by applying heat?
• Which metal does not contain iron, has good corrosion resistance but tarnishes and is non-magnetic?
• The property describing the extent to which a material can undergo plastic deformation before breaking is called what?
• Which resin, combined with a hardener, becomes hard and corrosion resistant, and is used for printed circuit boards and adhesives?
• Which is a listed disadvantage of global manufacturing?
• Which material is lightweight, strong, and corrosion resistant, used for drill bits, bikes, and aircraft?
• Which resin is typically used for electrical insulation in plug sockets and handles and is brittle if not reinforced?
• Which process specifically uses ammonia to introduce nitrogen into the surface to increase hardness?
• The ease with which a material can be machined with an acceptable surface finish without damaging the tool is called what?
• Which term refers to hardware items that have internal or external screw threads, such as screws, nuts and bolts?
• Which statement about water jet cutting is true?
• Which application of pigment to a surface adds aesthetics and resistance against wear and the elements?
• Which material is an alloy of copper and zinc?
• What is the name of the machine where the workpiece and/or cutting tools can be moved in many directions so that turning, boring and milling can be carried out without changing machines?
• The ability of a material to withstand a force that is applied to it is called what?
• The ability to not break when a force is applied suddenly is known as which property?
• How is the finished metal part recovered from the refractory mould in the investment casting process?
• Which material is used for car bodies and girders due to its ductility but is prone to rusting?
• Shape memory alloys have applications including actuation in safety devices and medical implants; which is a typical application mentioned?
• Which metal is well cast and has good machinability, is corrosion resistant, conducts heat well, and is an alloy of copper and zinc; used for musical instruments, screws, and water fittings?
• Which polymer's abbreviation stands for High Impact Polystyrene?
• Which resin forms a strong durable adhesive and is used with a hardener for electronics?
• Which advantage describes proximity to resources?
• Which metal category is magnetic and commonly used in structural components due to iron content?
• Which metal is ductile, malleable, resistant to corrosion, and is used for tin-plating for steel food cans against corrosion?
• Which machine bends plate or sheet metal by having a punch pressed into a die?
• Which alloy is resistant to corrosion, does not rust, with chromium, and used for cutlery, kitchen sinks, and surgical instruments?
• Which of the following is listed as an impact on the workforce due to automation?
• The ease with which a material can be hammered into shape without breaking is known as which property?
• Which process is described as similar to extrusion but forces heated granules into a mould?
• Which material has very good heat resistance, is very dark and hard, and is fairly brittle, used for saucepan handles?
• Which item is typically considered when assessing the cost of engineering materials?
• Which process forms plastic sheets by heating and using a vacuum on a single-surface mould?
• Which is an impact on material supply and control due to digital communications?
• Which machine is similar to a milling machine but uses softer materials, is less accurate, and the stage usually does not move?
• Which process typically involves dies compressing heated metal to shape parts?
• What is the process of using a drill bit to remove a circular area of material usually for fasteners called?
• The ability to absorb energy and resist fracture under impact defines which property?
• What is the process called where metal is heated and shaped by plastic deformation under compressive force?
• Which metal is used for tin-plating for steel food cans against corrosion?
• Which process flattens and smooths a surface using an abrasive moving belt?
• Which process forms large, simple hollow shapes by rotating a mould with heated material?
• The opposite of conductivity, describing resistance to transfer of heat or electricity, is called what?
• Which process uses two halves of a mould and a core to create metal parts, with the core typically destroyed after cooling?
• What is the name given to superalloys that can operate at high fractions of their melting point, used in aerospace and marine turbine engines?
• Which finish involves applying pigment by electrostatic spraying to create a wear-resistant surface layer?
• Which term best describes a screw that can tap its own hole when integrated into the material?
• The ability for a material to transfer heat or electricity is called what?