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Exhibit 2 Page 1 of 7
PART 1 - FRICTION MATERIALS STATUS REPORT NO. I 1
Vehicle Materials Development and Planning
June, I960
1
6001 1794 SCF-FORD-1994
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Exhibit 1
Page 3 of 7
ASBESTOS EUMTHATION - FRICTION MATERIALS CATEGORY
SECTION 2 - PRODUCT ENGINEERING REPORTS
I Activities Review - Brakes |
. Passenger Car Chassis - Asbestos free semi-met front disc brake pads were first used in the 1979 Mustang turbo option and Fairmont polioe package. Usage spread in I960 models to all Mustang, V8 Fairmont and T-Bird. 1981 usage will increase again to all Fax vehicles and Granada.' Bendix is the sole supplier. Semi-mete have proven the least expensive way to improve capacity. The trade off ie generally greater rotbr wear. All rear brakes are drum with asbestos containing lining.
A general asbestos-free lining development has been initiated by Car Chassis Brake Department with a letter to all the leading lining manufacturers. The letter invites manufacturers to demonstrate feasibility of asbestos free linings ty comparing per formance to current release over a single set of vehicle test parameters.
Light Truck - All 1980 model light truk
Lize semi-met front disc brake supplied
by Bendix. 'Rears are all drum typs^yip^ iBbestos containing shoes. No non-asbestos
substitutes are being investigat '
'
Heavy Truck - The ma^ oritjhf^oyd heavy trucks are equipped with drum brakes, front and rear, of conventional asbeptoB material. The very heavy class 16,000 to 20,000 pound capacity front axfytnracs utilize disc brakes with semi-met pads. There are
no plans to evaluate add&>6nal non-asbestos brake materials.
StatiBticB | - 6/80
Number of Bid Item Brakes
PE0
Front Car Chassis
Rear
Actual 1981 Model ! Total 1 j^Non-Abs
EBt. 1982 Model Total %Non-Abs
Est. 1985 Model Total joNon-Abs 1
Lt. Truck
Front --------Rear
Front Hvy. Truck
Rear
1
1
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1 1
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Exhibit 1 Page k of 7
ASBESTOS ELIMINATION - FRICTION MATERIALS CATEGORY . SECTION 2 - PRODUCT ENQINEERINO REPORTS '
Activities Review - Clutches 1
Transmission and Axle - T&A incentive
slop asbestos substitutions ha6 been
largely policy. All wet operatingShkfcabanial transmission clutch plates and bands
and'~lo>cckkiinngg ddiifferential clutch fiate^'have been converted to non-asbestos facing
as of (
).
A non-asbestos (fiberglass) compound, developed for manual transmission clutches by RaybeBtos, was used in production of 1980 200 CH) Fairmonts. The same material is currently released as an option to all conventional asbestos containing facingB. Production of non-asbestos clutches however, will be limited by Raybestos product- ' ion facilities until other sources are approved (Thermoid in process). Higher cost might also inhibit early release.
. Heavy Truck - clutch facings are being converted to ceramic materials as performance and costs become Imown. Conventional organics are not adequate.
. Light Truck - No non-asbesto6 substitutes have 6hovn equivalent performance to date. Possible development for Yuma with Asbai (Japan). Current 90? supplier, Thermoid, assures he can meet EPA proposed exposure limit. All facingB beginning Bl are seal coated for assembly safety.
I
PEO T&A Light Truck Beavy Truck
Number of End Product Clutches
Actual 1981 Model Total ?Non-Abs
Est. 1982 Model Total ?Non-Abs !
i
ii
Est. 1985 Model Total ?Non-Abs
!
ii
i
' _ _ _ _ _ _ 1_ _ _ _ 1 . i ;
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ASBESTOS ELIMINATION PROGRAM - FRICTION HA1 SECTION 3 - BACKGROUND TO CURRENT DESIGN iflffbcPf.
Exhibit 1 5 of ?
Brahes wd Hvy Duty Friction Applications
/
Asbestos has unique physical and chemical propertiW''which are veiy difficult to
reproduce in a substitute. These properties include a consistent natural lubricity, high temperature fimction, good permiability to heat generated gases, low cost. Furthermore, braking performance i6 judged against a highly developed (on asbestos) envelope of GPAS and FH7SS tests.
Three categories of non-asbestos compounds are currently being investigated.
1) Semi-metallics (Semi-met) - essentially spounge iron and Bteel vool plus graphite and borium sulfate held together in an organic matrix.
The graphite> i's_required td_preVent_welding to the drum or rotor but..has a. very....
low coefficient"of friction"when wet - it effectively restricts passenger car
use to power disc brakes; although they have been applied to heavy trucks.
.
Semi-met disc brake pads supplied by Bendix today for car and light truck are a composite eandwich of semi-met surface bonded to a reinforced organic back ing in turn riveted to a conventional steel pad. The sandwich construction iB used primarily because the semi-met material does not have the compressive strength for riveting.
2) Sintered metallics - mixtures of iron and copper, some in variable density, used in clutch discs, aircraft brakes. Not likely to become feasible for automotive brakes.
3) Non-asbestos organic (N.A.O.) - essentially the same as the current a6besto6 shoes/pads but with other fibers such as glass. These would seem the best prospect as a substitute involving least product development but N.A.O. materials are not strong structurally & delaminate in the high speed manufacturing process used for passenger car drum brakes. They are compatible with less automated process used in some large truck drum brakes.
Consensus among passenger car product engineers and suppliers i6 that an N.A.O. material would require a three to five year combined development of drums, shoes, and linings before release.
Regulation and General Corporate Policy
(TBD ) tonB of asbestos are released to the environment annually as a result of wear of friction material containing asbestos.*' There is a strong difference in pro fessional opinion as to the hazard from wear debris. High temperatures and pulverizing during wear change asbestos into a different form. The disagreement is to the toxicity of the debris.
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PRODUCED BY FORD
Section 3 Page 2
Exhibit 1
Page 6 of 7
Tiofrulatlon and General Corporate Policy (continued)
There ie no doubt, however, that asbestos mining and manufacture of asbestos contain ing products will be increasingly regulated. Regulations will be in the form of airborn exposure limits, and banning of more products containing asbestos in a free con dition (as vs. a filler in gaskets end plastics). A ban on the use of asbestos containing friction material is not expeoted in the<near future but regulation will make them more costly and reduce their availability.' More information about regulations and the intentions of private sector leadership will be exposed at an EPA sponsored conference July lh, 1980 in Washington D.C. Mr. A. Anderson of the Scientific Lab will attend.
NAAO Car and Truck Policy on product usage of asbestos is defined in CEPL-lOs - with certain exceptions, "Newly designed components 6hould not contain asbestos".
1/ Bibliography item reference
Vehicle Materials Development and Planning June, 1980
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Responses trom PEOfc - Asbestos
1. Climate Control Division 2. Body and Electrical S. Engine Engineering 4. Ford Parts & Service Division 5. Transmission & Axle Engineering 6. Electrical & Electronics Division - 7. Truck and Recreation 8. Truck Operations 8. Chassis Engineering
Supplier Survey Request and Purchasing Activity Responses - Asbestos
10. Climate Control Division 11. Casting Division 12. Electrical & Electronics Division 13. Glass Division
Responses from PEO's - Chromium and Benzene
June 6,1980 000) 1741
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