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80C? i56 NON- ASBESTOS FRICTION MATERIALS--DEVELOIMEKT STATUS FEB 1979
VENDOR INCENTIVES HIGH COMPLIANCE COSTS POTENTIAL LEGAL/LIABILITY EXPENSES UNCERTAIN ASBESTOS SUPPLY, COST, QUALITY INCREASED PROFIT POTENTIAL POTENTIAL SALES TO GM (WHICH HAS NON-ASBESTOS TARGET DATE)
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VENDOR INHIBITIONS HIGH DEVELOPMENT AND TOOLING COSTS SHORTAGE OF SKILLED FORMULATORS AND PROCESS ENGINEERS LIMITED AVAILABILITY OF SOME ALTERNATE MATERIAL? UNKNOWN TOXICITY OF SOME NEW MATERIALS
OTHER FACTORS UNCERTAIN FUTURE REGULATIONS, ON ASBESTOS POTENTIAL FOREIGN COMPETITION
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A. E. Anderson 2/14/79
Machining and Wear Dept. Engg. end Res. Staff
HFM - 004153
. ASBESTOS CHARACTERISTICS USED IN FRICTION MATERIALS
PROPERTY
BRAKES
FRICTION'
6
WEAR
8
STRENGTH
7
FLEXIBILITY
7(P)
DM. STABILITY
8
HEAT RESISTANCE
6
CHEM. STABILITY PERMEABILITY
3
6
HARDNESS FAILURE MODES
4 6
DRY
CLUTCHES
6
7 9
7(p)
7 6
4
5 4
6
CLUTCHES
3
2 '2
2(P)
1 2 1 2 1
WET <
p 0 o 2 1S) 7
BANDS
3 3 3 4(P
2 2
1 2 1
CODE: 1, Least Important through 10, Most Important for product function
(P) Property important primarily for product processing - Denotes asbestos,on balance, is believed to have a negative product contribution
HFM - 004154
A. E. Anderson 2/14/79
Machining and W^r Dept. Engg and Res. 1 .'f
ASBESTOS REPLACEMENT CANDIDATES
boo2 ir>if
I THERE IS NO KNOWN DIRECT SUBSTITUTE FOR ANY CRITICAL APPLICATION, HENCE NEW FORMULATIONS MUST BE DEVELOPED, h
I OR SUITABLE BLENDS OF FIBERS MUST BE FOUND.
A,
FIBER FIBERGLASS carboij/graphite STEEL WOOL ARAMID (KEVLAR) MINERAL WOOL sisal/cotton WOLLASTONITE
(KSI) STRENGTH
200 200
70 400
150
70
150
(MAXg) TEMP. F
1300
4000
1600 700
3200 300
2700
(MAX.) LENGTH Contin. Contin.
10" Contin.
2" 0.2" 0.01"
(M /g) SURF. AREA
0.2
0.4
0.01 0.2
0.3
0.2 0.1
(jf/in3) COST
5 30
20
30
3
2
0.4
(tons/year) AVAILABILITY
250,000 500
10,000
7,500
ADEQUATE 600,000 100,000
-
ASBESTOS
240
1050
1"
A
60. 3
75,000 (Friction
materials only)
The above compilation does not contain all of the necessary properties for asbestos replacement, since many are determined by the choice of structure, binder, and other fillers. Dry friction materials are the most critical in this respect, and are sensitive to Moh hardness, softening temperature, surface energy, pH in water, etc.
H F M -004155
A. E. Anderson 2/14/79 Machining and Wear Dept. Engg. and-Res. Staff
ALTERNATE FI3ERS- -PROBLEMS FOR CRY FRICTION MATERIALS SUBSTITUTION
8&02 lb19
FIEERGLASS CARBON/GRAPHITE STEEL WOOL ARAMID (KEVLAR)
MINERAL WOOL sisal/cotton WCLLASTONUE
PROCESSING--HIGH BULK VOLUME POOR BINDER ADHESION LOW PERMEABILITY MELT/FLOW AT RUBBING INTERFACE *
-
POOR FRICTION WITH HIGH FILL LEVEIS------------------PROCESSING--HIGH BULK VOLUME LOW PERMEABILITY
REQUIRES MURK OXIDATION RESISTANT BINDER CRITICAL WRT WEAR AND RUSTING BEHAVIOR
LOW PERMEABILITY, BUT NO PROBLEM FOR SEM3METS
PROCESSING--HIGH BULK VOLUME LOWERS EOT FRICTION POOR BINDER ADHESION LOW PERMEABILITY
~
MAY BE ABJ?ASIVE TO CAST IRON AND MUD STEEL BREAKS UP WITH HEAVY MIXING ACTION LOW PERMEABILITY
LOW TEMPERATURE RESISTANCE
WATER SENSITIVITY
i
GREEN FADE AT HIGH FILL LEVELS
POOR DIMENSIONAL STABILITY
IOW STRENGTH, ESPECIALLY BEFORE CURING
IOW PERMEABILITY
.
- 004156
A. E. Anderson 2/l?i/79 Machining and Wear Dept. Engg. and Res. Staff
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MON-ASBESTOS STATUS FOR DRY FRICTION MATERIALS
PASS. CAR AND LT. TRUCK DRUM BRAKES DISC BRAKES CLOTCII PACINGS
ABEX BENDIX R-M
RD
D
R D* U
NR
D
THERMOID THIOKDL OTHER U.S. OTHER FOREIGN 1.
i 1 ']
R
R
U(MET.)
N
RDN
N
U
N
U(MET.)
u(beral/kevlar)
HEAVY TRUCK DRUM BLOCK H.D. DISC BRAKES CLUTCH PACINGS
DR D N N N
N
RR
DN
N
r(met. )
N
*
NN
R
R
N
U(MET.)
N
TRACTOR
DRUM BRAKES
NR
R
N
N
U(MET.)
N
CLUTCH FACINGS
NA
R
D
N
U(MET.)
N
* Semimet linings with resin-asbestos backing now in production usage. Bendix claim a non-asbestos backing material has been found which appears suitable and will be available for testing shortly.
CODES
A Accepted and available
U Unaccepted, but available
,-
D Development stage--planned availability for calendar 1979
R Research stage--planned availability after calendar 1980
N No known activity
A. E. Anderson 2/14/79 Machining and Near Dept Engg. and Res. S 'f
*
'ft
HFM - 004157
NON-ASBESTOS STATUS FOR WET FRICTION MATERIALS
CLUTCHES AND DISCS PAPER TYPE resin/fiber resin/graphue SEMI METALLIC METALLIC
R-M
A R D N(S) U
`
EW-SD
A R N N N
OTHER
N N A N A
BANDS PAPER yYPE MILLBOARD resin/fiber SEMI METALLIC
A A R N(S)
A A N N
N N N N
CODES:
A Accepted and available
U Unaccepted, but available
D Development stage--planned availability for 1979
R Research stage--planned availability after 1986
N No known activity
,'
R002 1S21
f
I I*
1
HFM -004158
A. E. Anderson 2/14/79
Machining and W< Dept. Engg. and Res. S^aff
s
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860P00
TON-ASBESTOS FRICTION MATERIALS--DEVELOPMENT STATUS FEB 1979
VENDOR INCENTIVES HIGH COMPLIANCE COSTS POTENTIAL LEGAL/LIABILITY EXPENSES UNCERTAIN ASBESTOS SUPPLY, COST, QUALITY INCREASED PROFIT POTENTIAL FyiElfEiAIr^ffl2!B*TO*,<JM*T{WHICHHAB N0ft-ASBB8TO8 TAHUJST "BRIB)1
VENDOR INHIBITIONS HIGH DEVELOPMENT AND TOOLING COSTS SHORTAGE OF SKIUED F0RMULAT0R8 AND PROCESS ENGINEERS LIMITED AVAILABILITY OF SOME ALTERNATE MATERIALS UNKNOWN TOXICITY OF SOME NEW MATERIALS
OTHER FACTORS UNCERTAIN FUTURE REGULATIONS, ON ASBESTOS POTENTIAL FOREIGN COMPETITION
I) 1 'p.rf/ ;
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A
T#N .
A. E. Anderson s/lt/79
Machining and Wear Dept. Engg. and Res. Staff
PRODUCED B Y FORD
at in T" oo
u_ X
PRODUCED B Y FORD
{ ASBESTOS CHARACTERISTICS USED IN FRICTION MATERIATS
6601^00
PROPERTY
BRAKES
DRY CLUTCHES
CLUTCHES
WET 1"
BANDS
FRICTION
6
63
<3
WEAR STRENGTH FLEXIBILITY DIM. STABILITY
8 7 7(P) 8
7 9' 7(P) i 7
2 2 2(P) 1
3 3 4(P 2
HEAT RESISTANCE !
CHEM. STABILITY
PERMEABILITY i
HARDNESS
FAILURE MODES i
6 3 6 4 6
62 451 42 61
2 v 2 1
i CODE:
i
i
1, Least Important through 10, Most Important for product function (P) Property important primarily for product processing
^
- Denotes asbestos,on balance, is believed to have a negative product contribution
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A. E. Anderson 2/14/79
Machining and W**r Dept.
^g
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Engg and Rea. ,'f
` $2
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S u. z
00l.fr00
ASHESTOS REPLACEMENT CANDIDATES
THERE IS NO KNOWN DIRECT SUBSTITUTE FOR ANY CRITICAL APPLICATION. HENCE NEW FORMULATIONS MUST HE DEVELOPED, OR SUITABLE BLENDS OF FIBERS MUST BE POUND,
i
FIBER
'
(KSI) STRENGTH
(MAXq) TEMP. F
(MAX.) U3NGTH
(M2/g) . SURF. AREA
(f*/in3) COST
(tons/year). AVAILABILITY
,,i 1 11
f
,
FIBERGLASS carbon/orAFHITE STEEL WOOL ]
200 200
70
1300 4000 1600
Contln. Centin.
10"
0.2 0.4 0.01
5 30 20
250,000
500 10,000
-
1
ARAM3D (KEVLAR) MINERAL WOOL
400 150
700 3200
Contln. 2" .
0.2 0.3
30 3
7,500 __ * ADEQUATE
,,
'
sisal/cotton
70
300 0.2"
0.2 -2
600,000
WOLLASTONHE
1
ASBESTOS
1 '
150 240
2700 1050
0.01" 1"
0.1 60.
0.4
100,000
'
f
3 75,000 (Friction , materials only)
The above compilation doea not contain all of the necessary properties for asbestos replacement, since many are determined by the choice of structure, binder, and other fillers. Dry friction materials are the most critical in this respect, and are sensitive to Moh hardness, softening temperature, surface energy, pH in water, etc.
A. E. Anderson 2/14/79 Machining and Wear Dept. Engg. and Res. Staff
PRODUCED B Y FORD
<T"0 o o
Li.
X
ALTERNATE FIBERS- -FROBUMS FOR DRY FRICTION MATERIALS SUBSTITUTION
101F00
FIBERGLASS carbon/grafhite STEEL WOOL ARAMID (KEVLAR)
MINERAL WOOL sisai/cOtton WOLLASTONITE
PROCESSING--HIGH BULK VOLUME
FOOR BINDER ADHESION LOW PERMEABILITY
MELT/FLOW AT RUBBING INTERFACE
*
f , ft,.
1
POOR FRICTION/WITH HIGH FILL IEVEIS----------------------------------------------- ----
PROCESSING--HIGH BULK VOLUME
,
LOW PERMEABILITY
REQUIRES MORE OXIDATION RESISTANT BINDER CRITICAL WRT WEAR AND RUSTING BEHAVIOR LOW PERMEABILITY, BUT NO FROBUM FOR 8EMIMET3
FROCESSINC--HIGH BULK VOLUME
LOWERS HOT FRICTION
t
POOR BINDER ADHESION
LOW HiRMEABILITY
, '
.
MAY BE ABRASIVE TO CAST IRON AND MIID STEEL
BREAKS UP WITH HEAVY MIXING ACTION
LOW PERMEABILITY
,
LOW TEMPERATURE RESISTANCE WATER SENSITIVITY GREEN FADE AT HIGH FILL LEVELS
POOR DIMENSIONAL STABILITY
1
LOW STRENGTH, ESPECIALLY BEFORE .CURING
LOW PERMEABILITY
,
'
A. E. Anderson 2/J7i/79 Machining and Wear Dept Engg. and Res. Staff
zvivm
NON-ASBESTOS STATUS FOR DRY FRICTION MATERIALS
PASS. CAR AND LT.. TRUCK DRUM BRAKES DISC BRAKES CLUTCH FACINGS
ABEX BENDIX R-M
RD
D
R D* U
NR
D
THERMOID THIOKDL OTHER U.S. OTHER FOREIGN
R
R
u(met.)
N
'
R DN
N
U
N
U(MET.)
u(eeral/kevlar)
HEAVY TRUCK
DRUM BLOCK H.D. DISC BRAKES CLUTCH FACINGS
DR D N N N
N
RR
D
N
N
r(met.)
N
'
NN
R iR
N
U(MET.)
N
TRACTOR
1
DRUM BRAKES
NR
R
H
N
u(met.)
N
CLUTCH FACINGS
NA
R
D
N
U(MET.)
N
* Semlmet linings with resin-asbestos backing now in production usage. Bendix claim a non-asbestos backing material has been found which appears suitable and will be available for testing shortly.
CODES:
A Accepted and available
U Unaccepted, but available
D Development stage--planned availability for calendar 1979
R Research atage-- planned availability after calendar 1980
N No known activity
A. E. Anderson 2/l4/79
c Machining and Wear Dept. Engg. and Res. S "f
PRODUCED BY FORD
co <0 o o
2
u. X
MOW-ASBESTOS STATUS FOR WET FRICTION MATERIALS
CLUTCHES AND DISCS PAPER TYPE resin/fiber RESM/GRAPHHE SEMI METALLIC METALLIC
R-M
A R D H(S) 'U
BW-SD
A R H N H
OTHER
N N A N
A
BAWDS . PATER TYPE MILLBOARD RESIN/FIBER SEMI METALLIC
A A R H(s)
A A N N
N H N N
CODES:
A Accepted and available 0 Unaccepted, but available D Development s^age--planned availability for 1979 R Research stage--planned availability after *1980 N Ho known activity
E01V00 i
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A. E. Anderson 2/l*i/79 Machining and W< Dept. Engg. and Res. Swiff
, "
PRODUCED B Y FORD
.^ S2 g o
LL
X