Abstract: A method of forming a disk brake pad having a friction member composed of a bonding layer having a low porosity and a matrix layer having a high porosity and laminated on the bonding layer. The method does not require a pre-forming step. A material formed by pelletizing a mixture of components for the friction member and a non-pelletized material are fed one after the other into a cavity defined by a mold and a back plate. Also, since the pelletized material is compacted beforehand, the bonding layer formed from the pelletized material exhibits a sufficiently low porosity, so that the bonding layer can prevent moisture from infiltrating therethrough. Thus, the back plate is less likely to develop rust. Also, the bonding strength between the back plate and the bonding layer is improved. Further, since pelletized material forming the bonding layer penetrates into the matrix layer in a complicated manner, the bond strength between the bonding layer and the matrix is also improved.

Abstract: Foundry sand grains coated with a binder composition which comprises 100 wt. parts of methylolmelamine or alkylated methylolmelamine and 5 to 100 wt. parts of a water-soluble organic compound having a hydroxyl group. The sand grains coated with the composition are effective in a low-temperature foundry, especially for forming a core in an aluminum-alloy foundry.