Federal-Mogul Two-Dimensional Ultrasonic Inspection Technique Enables High Performance Pistons

The development of a novel two-dimensional (2D) ultrasonic analysis system
allows Federal-Mogul Corporation (NASDAQ: FDML) to create a new generation
of high performance pistons that enable a substantial further step in diesel
engine downsizing. In its first application, the greatly improved cooling
capability of the company's "raised gallery" piston allowed a Federal-Mogul
customer to achieve a CO2 reduction of up to 30 percent compared with the
previous generation engine without raised gallery pistons. The first production
application of Federal-Mogul's raised gallery piston also delivers a specific
power increase of 25 percent, keeping the piston at temperatures much lower
than the acceptable limit of 400degC. In the same conditions, a standard
piston's bowl rim stresses are 43 percent higher and its temperature reaches
440degC.

"Diesel downsizing increases specific power output in order to improve fuel
economy and CO2 emissions and also increases the thermal and mechanical
loads that diesel pistons must withstand," said Gian Maria Olivetti, Federal-
Mogul's vice president for technology and innovation, Powertrain Energy. "With
the development of new highly-loaded engines, the risk of piston failure has
increased substantially as past improvements in materials, design and cooling
concepts have reached their physical limits. Federal-Mogul's innovation in
advanced testing techniques, materials science and manufacturing processes
greatly reduces the limitations placed on diesel downsizing strategies."

Modern diesel pistons have a cooling gallery, through which oil flows
continuously. The position and design of the gallery have a significant impact
on the component's operating temperature and durability. The closer the gallery
is to the piston bowl, the more heat that can be removed, allowing engine
manufacturers to increase combustion temperatures and pressures to improve
fuel economy and CO2 emissions.

Standard, one-dimensional ultrasonic testing can identify defects but cannot
quantify their size and position. Federal-Mogul's 2D ultrasonic process,
however, provides 125,000 data points in

30 seconds. The technique enables Federal-Mogul engineers to accurately
determine the size and position of defects, providing valuable data for casting
process development. The detailed information provided also ensures
consistent quality in the finished high-precision components.

"In the past, it has been very difficult to cast a piston with optimal size and
location of the cooling gallery," said Dr. Frank T.H. Doernenburg, Federal-Mogul
director of technology, pistons and pins." Federal-Mogul's new 2D ultrasonic
test has removed that barrier. Our process is non-destructive, completely
controls casting process quality and aids advanced casting process
development, giving engine designers substantially more freedom to increase
engine efficiency."

Federal-Mogul validated its 2D ultrasonic technology by dissecting and
sampling hundreds of pistons, correlating the ultrasonic images against
destructive testing methods. The research resulted in the development of
software tools as well as a number of key physical parameters such as probe
geometry, wavelength, beam geometry and focus.

Piston performance can be increased significantly through Federal-Mogul's 2D
ultrasonic testing and analysis process, which is quickly becoming an enabling
technology for more efficient powertrains. This breakthrough in inspection
technology was developed at the company's Nuremberg technical centre and
was recently awarded a 2012 Automotive News PACE Award.

About Federal-Mogul

Federal-Mogul Corporation is a leading global supplier of powertrain and safety
technology and innovation to improve fuel economy, reduce emissions and
enhance vehicle safety. The company serves the world's foremost original
equipment manufacturers of automotive, light, medium-, heavy-duty,
aerospace, marine, rail and off-road vehicles; and industrial, agricultural and
power-generation equipment; as well as providing well-known brands in the
global aftermarket. Federal-Mogul's world-class global engineering, lean
manufacturing and distribution network deliver best-in-class quality products
and services at competitive cost. The company's sustainable global profitable
growth strategy creates value and satisfaction for its customers, shareholders
and employees. Federal-Mogul was founded in Detroit in 1899. The company is
headquartered in Southfield, Michigan, United States and employs 45,000
people in 34 countries. The company's website is www.federalmogul.com.