btec level 2 technical diploma in engineering...question number answer mark 18 award 1 mark for...

UNIT 2: PROCESSES AND MATERIALS

BTEC Level 2 Technical Diploma inENGINEERING

First teaching: September 2017 | First certification: Summer 2018ISSUE 1

SAMPLE ASSESSMENT MATERIALS (SAMs)

Edexcel, BTEC and LCCI qualifications

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About Pearson

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References to third-party material made in this specification are made in good faith. We do not endorse, approve or accept responsibility for the content of materials, which may be subject to change, or any opinions expressed therein. (Material may include textbooks, journals, magazines and other publications and websites.)

ISBN 978 1 4469 4581 0 All the material in this publication is copyright © Pearson Education Limited 2016

Edexcel, BTEC and LCCI qualifications

Edexcel, BTEC and LCCI qualifications are awarded by Pearson, the UK’s largest awarding body offering academic and vocational qualifications that are globally recognised and benchmarked. For further information, please visit our qualification websites at www.edexcel.com, www.btec.co.uk or www.lcci.org.uk. Alternatively, you can get in touch with us using the details on our contact us page at qualifications.pearson.com/contactus

About Pearson

Pearson is the world's leading learning company, with 40,000 employees in more than 70 countries working to help people of all ages to make measurable progress in their lives through learning. We put the learner at the centre of everything we do, because wherever learning flourishes, so do people. Find out more about how we can help you and your learners at qualifications.pearson.com

References to third-party material made in this specification are made in good faith. We do not endorse, approve or accept responsibility for the content of materials, which may be subject to change, or any opinions expressed therein. (Material may include textbooks, journals, magazines and other publications and websites.)

ISBN 978 1 4469 4581 0 All the material in this publication is copyright © Pearson Education Limited 2016

1Pearson BTEC Level 2 Technical Diploma in Engineering – Unit 2 Processes and Materials–Final Sample Assessment Materials – Issue 1 – December 2016 © Pearson Education Limited 2016

2 Pearson BTEC Level 2 Technical Diploma in Engineering – Unit 2 Processes and Materials–Final Sample Assessment Materials – Issue 1 – December 2016 © Pearson Education Limited 2016

Unit 2: Processes and Materials Mark Scheme

General marking guidance

• All candidates must receive the same treatment. Examiners must mark the first candidate in exactly the same way as they mark the last.

• Mark schemes should be applied positively. Candidates must be rewarded for what they have shown they can do, rather than be penalised for omissions.

• Examiners should mark according to the mark scheme, not according to their perception of where the grade boundaries may lie.

• All marks on the mark scheme should be used appropriately. • All the marks on the mark scheme are designed to be awarded. Examiners should

always award full marks if deserved, i.e. if the answer matches the mark scheme. Examiners should be prepared to award zero marks if the candidate’s response is not worthy of credit according to the mark scheme.

• Where some judgement is required, mark schemes will provide the principles by which marks will be awarded and exemplification may be limited.

• When examiners are in doubt regarding the application of the mark scheme to a candidate’s response, the team leader must be consulted.


Section A

Questionnumber

Answer Mark

1 The ability of a material to resist chemical attack (1)

Questionnumber

Answer Mark

2 The ability of a material to withstand wear, abrasion or indentation (1)

Questionnumber

Answer Mark

3 Toxic materials:

Wear eye protection:

(2)

Questionnumber

Answer Mark

4 Non-ferrous (1)

Questionnumber

Answer Mark

5

(2)

Channel Pipe

Questionnumber

Answer Mark

6 Kevlar (1)

Questionnumber

Answer Mark

7 Product Material

(2)

QuestionNumber

Answer Mark

8 (1)

Cast iron

Bronze

Carbon steel

Carbon fibre

Natural rubber


Questionnumber

Answer Mark

9 table (1)

Questionnumber

Answer Mark

10 Any two of the following:• drilling/centre drilling• parallel turning• taper turning• facing off• screw cutting• counterboring• countersinking• chamfering• boring• parting off• knurling• tapping.

Accept any appropriate response.

(2)

Questionnumber

Answer Mark

11

Ice cube tray

(1)

Questionnumber

Answer Mark

12 Sheet (1)

Questionnumber

Answer Mark

13 • Dividers• Steel rule

(2)

Questionnumber

Answer Mark

14 Tempering (1)

Questionnumber

Answer Mark

15 Electrochromic (1)

Questionnumber

Answer Mark

16 Thermal conductivity

• The ability of material to transmit heat energy by conduction.

• The ability of a material to retain heat.

• The ability of a material to pass heat along its length/along its body/through its mass.

Accept any other appropriate response.

Transparency

• The ability of a material to allow light through it without distortion.

• The ability of a material to allow light to pass straight through it.

• A material that lets you see through it.


(2)

Questionnumber

Answer Mark

17 Award 1 mark for identifying an advantage and a further 1 mark foran extension, up to a maximum of 2 marks for each response. Maximum of 4 marks.Any two advantages from the following.

• A CNC machine can be quicker than a conventional machine for identical components (1) because a conventional machine has to be manually adjusted/operated (1).

• A CNC machine gives more consistent quality/improved accuracy (1) because human error is limited, unlike with conventional machining techniques (1).

• It is more efficient than requiring skilled operators to interpret specifications/drawings each time (1) as the CNC machine uses a pre-programmed set of instructions (1).


(4)


Questionnumber

Answer Mark

9 table (1)

Questionnumber

Answer Mark

10 Any two of the following:• drilling/centre drilling• parallel turning• taper turning• facing off• screw cutting• counterboring• countersinking• chamfering• boring• parting off• knurling• tapping.

Accept any appropriate response.

(2)

Questionnumber

Answer Mark

11

Ice cube tray

(1)

Questionnumber

Answer Mark

12 Sheet (1)

Questionnumber

Answer Mark

13 • Dividers• Steel rule

(2)

Questionnumber

Answer Mark

14 Tempering (1)

Questionnumber

Answer Mark

15 Electrochromic (1)

Questionnumber

Answer Mark

16 Thermal conductivity

• The ability of material to transmit heat energy by conduction.

• The ability of a material to retain heat.

• The ability of a material to pass heat along its length/along its body/through its mass.


Transparency

• The ability of a material to allow light through it without distortion.

• The ability of a material to allow light to pass straight through it.

• A material that lets you see through it.


(2)

Questionnumber

Answer Mark

17 Award 1 mark for identifying an advantage and a further 1 mark foran extension, up to a maximum of 2 marks for each response. Maximum of 4 marks.Any two advantages from the following.

• A CNC machine can be quicker than a conventional machine for identical components (1) because a conventional machine has to be manually adjusted/operated (1).

• A CNC machine gives more consistent quality/improved accuracy (1) because human error is limited, unlike with conventional machining techniques (1).

• It is more efficient than requiring skilled operators to interpret specifications/drawings each time (1) as the CNC machine uses a pre-programmed set of instructions (1).


(4)


Questionnumber

Answer Mark

18 Award 1 mark for identifying an advantage and a further 1 mark for an extension, up to a maximum of 2 marks for each response. Maximum of 4 marks.

Any two advantages from the following.

• No possibility of corrosion (1), which increases the frame life and reduces costs (1).

• Improved fatigue resistance (1) as carbon fibre composites are less likely to fail due to the vibration of the road (1).

• Better strength to weight ratio (1), allowing increased bicycle speed (1).

• Can be shaped to produce aerodynamic shape (1), suiting different cycling disciplines such as track or road racing (1).

• A more comfortable ride (1) as frames can be custom designed for individual needs (1).


(4)

Section B

Questionnumber

Answer Mark

19 Product Surface treatment

Road side barrier

Wheel brace handle

(2)

Questionnumber

Answer Mark

20 A linked response, award 1 mark for identifying an advantage and a further 1 mark for an extension, up to a maximum of 2 marks for each response. Maximum of 4 marks.

• Better durability/longer life span (1) because the reacted finish integrates with the underlying aluminium (1).

• Easier to maintain (1) as it is a tougher surface finish than the untreated aluminium (1).

• Anodising makes the wheels more customisable/appealing to customers (1) because it comes in a wider range of colours than the untreated aluminium (1).

• The wheels will have excellent colour stability (1) because the anodised finish will not fade when exposed to the sun (1).


(4)

Galvanising

Hardening

Polishing

Etching

Plastic coating


Questionnumber

Answer Mark

21 A linked response, award 1 mark for identifying a benefit [way] and a further 1 mark for an extension, up to a maximum of 2 marks.

• PO does not have to work in hazardous conditions near the anodising tank (1), which minimises the risk of health problems (1).

• It is a more comfortable working environment for the PO (1) because they do not have to wear as much PPE (1).

• PO does not get injuries due to fatigue from lifting the wheels (1) as robots can continuously lift heavy loads (1).

• It makes the PO role more accessible to a wider range of people (1) because there is no barrier for physical disability/requirement for physical strength to manipulate the wheel into position (1).


(2)

Questionnumber

Answer Mark

22 Any two of the following:

• put waste in the correct recycling receptacles

• try to reuse excess materials

• choose the correct form of supply

• tessellate when preparing materials

• minimise own errors/work more precisely.


(2)

Questionnumber

Answer Mark

23 Award 1 mark for identifying a reason and a further 1 mark for extension, up to a maximum of 2 marks.

• Bumpers can be manufactured in one piece (1), reducing the need for further machining (1).

• Efficient manufacturing process (1) as parts can be mass produced (1).

• Quick cycle times (1), allowing product demand to be met (1).

• Little or no waste produced (1) as reject parts can be recycled (1).


(2)

Questionnumber

Answer Mark

24 Award 1 mark for identifying a reason and 1 mark for extension, up to a maximum of 3 marks.

• Poor corrosion resistance (1) impacting on product aesthetics (1), leading to reduced product life (1).

• Heavier material (1) putting increased stress on the fence posts (1), leading to damage which leads to unhappy customers (1).

• Increased costs (1) as additional treatment required (1) to prevent corrosion (1).

Accept any other appropriate alternatives.

(3)


Questionnumber

Answer Mark

21 A linked response, award 1 mark for identifying a benefit [way] and a further 1 mark for an extension, up to a maximum of 2 marks.

• PO does not have to work in hazardous conditions near the anodising tank (1), which minimises the risk of health problems (1).

• It is a more comfortable working environment for the PO (1) because they do not have to wear as much PPE (1).

• PO does not get injuries due to fatigue from lifting the wheels (1) as robots can continuously lift heavy loads (1).

• It makes the PO role more accessible to a wider range of people (1) because there is no barrier for physical disability/requirement for physical strength to manipulate the wheel into position (1).


(2)

Questionnumber

Answer Mark

22 Any two of the following:

• put waste in the correct recycling receptacles

• try to reuse excess materials

• choose the correct form of supply

• tessellate when preparing materials

• minimise own errors/work more precisely.


(2)

Questionnumber

Answer Mark

23 Award 1 mark for identifying a reason and a further 1 mark for extension, up to a maximum of 2 marks.

• Bumpers can be manufactured in one piece (1), reducing the need for further machining (1).

• Efficient manufacturing process (1) as parts can be mass produced (1).

• Quick cycle times (1), allowing product demand to be met (1).

• Little or no waste produced (1) as reject parts can be recycled (1).


(2)

Questionnumber

Answer Mark

24 Award 1 mark for identifying a reason and 1 mark for extension, up to a maximum of 3 marks.

• Poor corrosion resistance (1) impacting on product aesthetics (1), leading to reduced product life (1).

• Heavier material (1) putting increased stress on the fence posts (1), leading to damage which leads to unhappy customers (1).

• Increased costs (1) as additional treatment required (1) to prevent corrosion (1).


(3)


Questionnumber

Answer Mark

25 Advantages of using machining:

• accuracy in producing the centre plate hole

• easy set-up to machine plate

• excellent surface finish can be achieved

• fast production rate during rough cutting

• low set-up costs

• ideal for batch production

• hole sizes and positions can be accurately produced

• able to machine complex parts

• waste is recyclable

Disadvantages of using machining:

• waste material generated when parallel turning

• time consuming to machine bore with tight tolerance

• to carry out more than one machining operation several machine changes are require

• inconsistent dimensions are possible

Advantages of using sand casting:

• can produce one mould to make multiple plates

• consistent quality products

• fast production rate

• potential to use for future orders


• appropriate surface finish produced for outside

• a very quick process to obtain a near complete product

Disadvantages of using sand casting:

• further machining required

• high energy consumption process

• not ideal for batch production but has the potential with future orders

• high tooling costs for a batch of 20

(6)

Level Mark Descriptor

0 No rewardable material.

1 1–2 Basic arguments for both processes or only one side considered. The answer is likely to be in the form of a list. Points made will be superficial/generic and not applied/directly linked to the situation in the question. Response only considers one side of the argument. Conclusion, if present, is invalid or unsupported. Learners show limited understanding of both processes.

2 3–4 Arguments for and against both processes but there will be more emphasis on one process than the other. Considers both sides of the argument but is unbalanced. There is an attempt at a conclusion but it may not be fully justified and the link to the situation will not always be clear. Learners show a good understanding of both processes.

3 5–6 Balanced argument for and against each process. The argument will be justified and clearly linked to the consideration of arguments for and against, and their relative importance to the situation. A conclusion is produced that is relevant and clearly linked to the situation. Learners show a developed understanding of both processes.

Questionnumber

Answer Mark

26 A linked response, award 1 mark for identifying a benefit and a further 2 marks for an extension, up to a maximum of 3 marks.

• Surface mount technology can produce circuits very quickly (1), meaning production costs are lower (1) which will mean less time between fulfilling orders (1).

• Surface mount technology can produce high quality circuits (1), which means less failures before they are assembled into the laptop (1) ensuring that there are less customers returns/complaints/more returning customers (1).

• Surface mount technology uses less labour (1), meaning the overall wage bill will be less (1) and prices can be lowered to sell more/and prices remain the same but making more profit/contribution (1).

• Allows smaller components to be made (1), which means that more features can be put into the laptop without making it bigger (1) so that it is more attractive to customers (1).


(3)


Questionnumber

Answer Mark

25 Advantages of using machining:

• accuracy in producing the centre plate hole

• easy set-up to machine plate

• excellent surface finish can be achieved

• fast production rate during rough cutting

• low set-up costs

• ideal for batch production

• hole sizes and positions can be accurately produced

• able to machine complex parts


Disadvantages of using machining:

• waste material generated when parallel turning

• time consuming to machine bore with tight tolerance

• to carry out more than one machining operation several machine changes are require

• inconsistent dimensions are possible

Advantages of using sand casting:

• can produce one mould to make multiple plates

• consistent quality products

• fast production rate

• potential to use for future orders


• appropriate surface finish produced for outside

• a very quick process to obtain a near complete product

Disadvantages of using sand casting:

• further machining required

• high energy consumption process

• not ideal for batch production but has the potential with future orders

• high tooling costs for a batch of 20

(6)

Level Mark Descriptor


1 1–2 Basic arguments for both processes or only one side considered. The answer is likely to be in the form of a list. Points made will be superficial/generic and not applied/directly linked to the situation in the question. Response only considers one side of the argument. Conclusion, if present, is invalid or unsupported. Learners show limited understanding of both processes.

2 3–4 Arguments for and against both processes but there will be more emphasis on one process than the other. Considers both sides of the argument but is unbalanced. There is an attempt at a conclusion but it may not be fully justified and the link to the situation will not always be clear. Learners show a good understanding of both processes.

3 5–6 Balanced argument for and against each process. The argument will be justified and clearly linked to the consideration of arguments for and against, and their relative importance to the situation. A conclusion is produced that is relevant and clearly linked to the situation. Learners show a developed understanding of both processes.

Questionnumber

Answer Mark

26 A linked response, award 1 mark for identifying a benefit and a further 2 marks for an extension, up to a maximum of 3 marks.

• Surface mount technology can produce circuits very quickly (1), meaning production costs are lower (1) which will mean less time between fulfilling orders (1).

• Surface mount technology can produce high quality circuits (1), which means less failures before they are assembled into the laptop (1) ensuring that there are less customers returns/complaints/more returning customers (1).

• Surface mount technology uses less labour (1), meaning the overall wage bill will be less (1) and prices can be lowered to sell more/and prices remain the same but making more profit/contribution (1).

• Allows smaller components to be made (1), which means that more features can be put into the laptop without making it bigger (1) so that it is more attractive to customers (1).


(3)


Questionnumber

Answer Mark

27 Advantages of using aluminium:

• lightweight

• corrosion resistant

• ductile (can be easily formed into a variety of shapes)

• recyclable

• aesthetic qualities may provide a key selling point

• non-toxic

Disadvantages of using aluminium:

• expensive

• electrical conductor

• would require anodising or powder coating

• generated from finite resources

Advantages of using ABS:

• lightweight

• tough

• hard

• recyclable

• can be injection moulded

• electrical insulator

• no further treatment required

Disadvantages of using ABS:

• low heat resistance/melting point

• flammable and smoke is toxic

• appearance can degrade over time



(6)Level Mark Descriptor


1 1–2 Basic arguments for both materials or only one material considered. The answer is likely to be in the form of a list. Points made will be superficial/generic and not applied/directly linked to the situation in the question. Response only considers one side of the argument. Conclusion, if present, is invalid or unsupported. Learners show limited understanding of both materials.

2 3–4 Arguments for and against both materials, but there will be more emphasis on one material than the other. Considers both sides of the argument but is unbalanced. There is an attempt at a conclusion but it may not be fully justified and the link to the situation will not always be clear. Learners show a good understanding of both materials.

3 5–6 Balanced argument for and against each material. The argument will be justified and clearly linked to the consideration of arguments for and against, and their relative importance to the situation. A conclusion is produced that is relevant and clearly linked to the situation. Learners show a developed understanding of both materials.


Questionnumber

Answer Mark

27 Advantages of using aluminium:

• lightweight

• corrosion resistant

• ductile (can be easily formed into a variety of shapes)

• recyclable

• aesthetic qualities may provide a key selling point

• non-toxic

Disadvantages of using aluminium:

• expensive

• electrical conductor

• would require anodising or powder coating


Advantages of using ABS:

• lightweight

• tough

• hard

• recyclable

• can be injection moulded

• electrical insulator

• no further treatment required

Disadvantages of using ABS:

• low heat resistance/melting point

• flammable and smoke is toxic

• appearance can degrade over time



(6)Level Mark Descriptor


1 1–2 Basic arguments for both materials or only one material considered. The answer is likely to be in the form of a list. Points made will be superficial/generic and not applied/directly linked to the situation in the question. Response only considers one side of the argument. Conclusion, if present, is invalid or unsupported. Learners show limited understanding of both materials.

2 3–4 Arguments for and against both materials, but there will be more emphasis on one material than the other. Considers both sides of the argument but is unbalanced. There is an attempt at a conclusion but it may not be fully justified and the link to the situation will not always be clear. Learners show a good understanding of both materials.

3 5–6 Balanced argument for and against each material. The argument will be justified and clearly linked to the consideration of arguments for and against, and their relative importance to the situation. A conclusion is produced that is relevant and clearly linked to the situation. Learners show a developed understanding of both materials.


BTEC Level 2 Technical Diploma in

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ENGINEERING

SAMPLE ASSESSMENT MATERIALS (SAMs)

BTEC_L2_SAMs_Engineering_U2.indd 14 06/02/2017 14:25

btec level 2 technical diploma in engineering...question number answer mark 18 award 1 mark for...

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