copper use reporting program model year 2003 update mark phipps ph.d. product development manager...

Copper Use Reporting ProgramModel Year 2003 Update

Mark Phipps Ph.D.

Product Development Manager

Federal-Mogul Friction Products

Brake Pad PartnershipStakeholder ConferenceJune 22nd 2005

* BMC/PEC = Brake Manufacturers Council - Product Environmental Committee

Purpose of the Report

• Track trends in the use of copper in OE automotive brake pads.– Monitor the BMC/PEC* members voluntary

commitment to reduce the use of copper in the event that it is determined to be a significant cause of water impairment.

• Provide information for the fate and transport modeling studies

Data Strengths

• Best Data Available– Data provided by the manufacturer (BMC/PEC

members)• Coverage

– Reliable information on approx. 40% of total car and truck sales in each model year

• Trend Indicator– Indicates trends in the use of copper in brake pads

Data Limitations• Coverage

– ~60% of new cars sales not included

– The data covers new cars and light trucks. It does not include usage in:

• Aftermarket (replacement) brake pads

• Motorcycles

• Heavy duty trucks

• Off-road vehicles

• Rail cars

• Results are not designed for total mass load calculations– Only one of the several inputs needed

– Less than half of total new sales are included

– Does not reflect regional variations in fleet mix

– Regional driving patterns affect wear rates of brake linings

Data Generation• Voluntary submission of copper content by

BMC/PEC members• Proprietary information• Basis of “representative” wear debris sample• Vehicle selection (target is to sample ~40% of new car

sales)

– 1998 to 2001– Top 20 best selling vehicles.

– 2002 and 2003– 20 of the top 25 best selling vehicles.

(Actual Coverage: 1998 = 42.8% 1999 = 41.0% 2000 = 39.3%2001 = 39.7% 2002 = 39.4% 2003 = 42.1%)

Copper Monitoring ResultsModel Year 1998 1999 2000 2001 2002 2003

Copper per vehicle (kg) 0.0402 0.0517 0.0564 0.0561 0.0766 0.0769

Friction material pervehicle (kg)

1.406 1.314 1.256 1.238 1.183 1.161

• Trend in OE automotive industry towards larger brake systems and larger pads compared to previous model.

• Evidence of a slowing of the shift in material type from semi-metallic to NAO/Low Steel friction materials. (Semi-metallic generally do not contain copper; NAO and Low Steel usually contain copper or copper compounds.)