Document npmELNrQxOrvbnoLn6vGawX61

f $. S. Labana J. E. Mayer, Jr. Subject: Kon-Asbestos Friction Materials In view of the uncertainty of future regulations regnrdiu:* csiu-Rtos in friction materials and the economics/availability of quality ashc-Rtc-, w are proposing an e::pansion of our current friction material program Uta 'jJ to incluoo ronasb'itstos friction materials. A program proposal is attachco, dong with a copy of the Vehicle Materials Engineering Key Issue Report, Asbestos 1'sage -1. ( Af< /' ^ A. E +* ; / And^rcon Attachments / M. H. VJcintraub / -` / i / R. L.' Gealer / c t i\ PQ <*001 16*9 SCF-FORD-1413 Mew Program Proposal -1- t Non-Asbestos Frictional Materials * Objective * To develop and to evaluate non-asbe6tos friction material. So carry out tribo logical studies of non-asbestos brake linings on cast iron and aluminum drums and rotors. Introduction Asbestos is the major constituent in brake linings that are used for all of Ford's passenger vehicles. Airborne asbestos fibers can be generated in 8 work environment during the manufacturing and/or servicing of brakes. The allowable OSHA concentration for asbestos is presently 2 fibers/cc air snd is expected to be 0.5 fibers/cc air in early 1976. There also has been suggestions by KIOSH that this limit be lowered to 0.1 fibers/cc air. To reduce asbestos levels to 0.1 flber6/ce air or even to 0.5 fibers/cc sir from the current levels (about 1.2 fibers/cc air), lord's brake lining sup pliers will be forced to redesign existing equipment and/or install new processing equipment which will demand a large capital investment. One of our suppliers indicates that a level of 0.8 fibers/cc air could be achieved by modifying current processing equipment. There will be a reluctance by some of our suppliers to commit the neccbsary capital to convert existing plants to meet new standards because of the uncertainty of future regulations and their ability to meet then. Aleo government regulations may force non asbestos brake linings by restricting the servicing of brakes with asbestos brake lining materials. Thus, Ford's suppliers may be forced to abandon the current resin/asbestos composites in favor of an asbestos-free friction material. Unfortunately there are no asbestos-free brake linings currently available that will be satisfactory for normal customer usage. It is our understanding that both Inland and Delco-Moraine divisions of CM have developed, or are developing, asbest06-free brake linings. These materials appear to require different brake designs to provide optimal performance. To help ensure that acceptable asbestos-free formulations arc available, it is recommended that Research expand the friction material program to include the development of non-asbestos brake linings. This will enable Research Staff to gam the necessary expertise to assict in developing appropriate lining quality control tests, to determine failure modes, and to assist lining vendors when appropriate. Also this program would include studies of the best lining and brake geometries for use with the resultant non asbestos linings. Technical Approach A. Survey Options Vet Brakes Full Metallic Re6in-Bonded Metallic Resin-Fiber 8001 1650 t L < t < 5 Kev Program Proposal Non-Asbestos Frictional Materials Objective _ To develop and to evaluate non-asbestos friction tutorial. To carry out tribo logical studies of non-asbestos brake linings on cast iron and aluminum drums and rotors. Introduction Asbestos is the mjnr constituent In brake linings that arc used for all of Ford's passenger vehicles. Airborne asbestos fibers can be generated in a work environment during the manufacturing and/or servicing of brakes. The allowable OSKA concentration for asbestos is presently 2 fibers/cc air and is expected to be 0.5 fibers/cc air in early 1976. There also has been suggestions by JO OSH that this limit be lowered to 0.1 fioers/cc air. To reduce asbestos levels to 0.1 fibers/cc air or even to 0.5 fibers/cc air from the current levels (about 1.2 fibers/cc air), rord'6 brake lining sup pliers will be forced to redesign existing equipment end/or Install new processing equipment which will demand a large capital investment. One of our suppliers indicates that a level of 0.8 fibers/cc air could be achieved by modifying current processing equipment. There will be a reluctance by some of our suppliers to commit the necessary capital to convert existing plants to meet new standards because of the uncertainty of future regulations and their ability to meet them. Also government regulations may force non asbestos brake linings by restricting the servicing of brakes with asbestos brake lining materials. Thus, Ford's suppliers may be forced to abandon the current resin/asbestos composites in favor of an asbestos-free friction material. Unfortunately there are no asbestos-free brake linings currently available that will be satisfactory for normal customer usage. It is our understanding that both Inland and Delco-Moraine divisions of GM have developed, or are developing, asbestos-free brake linings. These materials appear to require different brake designs to provide optimal performance. To help ensure thBt acceptable asbestos-free formulations are available, it is recommended that Research expand the friction material program to include the development of non-asbestos brake linings. This will enable Research Staff to gain the necessary expertise to assist in developing appropriate lining quality control tests, to determine failure modes, end to assist lining vendors when appropriate. Also this program would include studies of the best lining and brake geometries for use with the resultant non asbestos linlngB. Technical Approach A. Survey Options Wet Brakes Full Metallic Resin-Bonded Metallic Resin-Fiber 8001 ltbl B .Evaluate Vendor Submissions United States Foreign C. Selected Laboratory Studies Carbon Fiber Metal Wire Filled Fiberglass Fiber Titanate Fiber Polymer Fiber D. System Optimization Lining Size and Shape Vented on Solid Rotor Rotor Material and Surface Finish Project Requirements The investigation will require the effort of 1 additional person in Polymer Science Department, 1 additional person in Machining and Wear Department, and 0.3 additional person in Technical Services. 8002 1631 PRODUCED BY FORD my ILSJUMUULfi gmna.I9JHllP5 { CELSEf-RITES Brtb fade Lining and Dnni nsDf 7H10X0L ` front flee fade fear Mae fade ns RATBEST05 Cloteh Facings Yt& Vao ao ao AUU 1 JERAL IKDBSTRIES Clutch dice eee'y friction faelnge Waahere 'icrrtN end KASCK Reactor . r.. fORTTR tnewoib tiv. Clutch Disc Shoe Lining Aae'j-front and Rear ns bo ns TES BDOII Shoe * Lining ns ao ao ao ao ao nss/ ns ao ns so NO TES ns tj compliance to present 2 fiber/cc etd* v/ present complience to proposed 5 fiber/cc Btd ( ability to meet 5 fiber/cc level VEHICLE MATERIALS ENGINEERING MAY 1977 'bonding Indeed of rlvetii* Kllnate Orlndl^-Noldad approac Induetrlal Hygiene Heaaural Bo lwadlate plane fur automa tion $J00,000 to ocagdy plua 010,000 annually Prooeet Wang# from Mfnuin to Injection aoldl^$1.2 mill loti lnraetaent-would reqcli requellfioatien Bon-aabeetoe aubetltnte peeently ereilahlo-CM year lead time for vehicle testing requl: Induetrlal Hygiene meaturei to approach 1 fiber/cc. Alternative Rev Hiterltli belnj eoneldered-glaet, mineral wool, coablMtlon of fiber. .All MD foeueed on non-aabeetoi preduete * / All pereonnel wearing bead ho< flltera 1001 of the time. Will oeeee operations If foroec to accept etandarde. Will atop manufacture of aebeei producte If forced to eeeept etanderd. fell 76 preeentatlon on noneebeetee clutch faelnge to fort negative reeponee-eoet equivali Ability to eoet facing! to redi flber/oc level et no extra coat Standard of .1 will prohibit aebeetoa uaage. Brake eubetltutea Inoraaaa vt. and eoet-ooe year lead time. 1.3 million to meet 1 flber/ee limit 5. 5 tUUn and 1-3 ?nt*M .5 fiber limit Iwoeiible to wot .1 level `Sealmetallic diet broket eebeetoe-free basking to b completed ftll-eott lncrwent 1.2-1.6 * weight Increment 1.8 x Mbergleia lininge or. drum-good In leb, not eo good on road. 'Critical lesue-no produet for drua brakee-L980-fil nodal /ear projection. Vat sanding A grlndl^ could be instituted. RC'01 165? rrt rr>v vsa * re.rs