I am a machinist\engeneering maintenance tech for Anheuser-Busch of 14 years. I have 10 years at other places before that.
If I were inspecting this thing I would pull off the caliper and look for forigen materail that perhaps lodged there or evidence of said. And if this had been the case it could have dislodged long ago. And perhaps when the pads were made somthing hard could have got into the mold? some of the other problems listed in this post could have come from lack of lubricant on the pad retainer bolts \pins inside the seals, preventing the pads from floating free and self adjusting.
But the bad news is brakes are a wear item and getting them repaired under warranty is a tough go. You would have to convince them of the defective materials or workmanship (no lube om the pins). You have your work cut out for you.
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