Abstract: To produce a sintered metal type brake friction element which beds-in quickly and which has a "feel" similar to a resin-based element, powdered metallic friction material is subjected to a resistance sintering or furnace sintering operation, so as to produce a sintered substrate and an unsintered or partly sintered surface layer which has less wear resistance than the substrate but friction properties which are not substantially less than the substrate. The surface layer may be formed of the same or different material as the substrate layer depending upon the sintering technique chosen.

Abstract: A friction element for a motor car or motor cycle disc brake is produced by pressing a powdered friction material in a die cavity using first and second resistance heating electrodes. The friction material is thereby sintered and bonded to a backing plate which closes one end of the die cavity. The first electrode has a backing plate-engaging end surface formed with a recess therein which is partly filled by a graphite insert which is less electrically conductive than the remainder of the first electrode. The second electrode may have a similar insert therein and may either engage the friction material directly or through the intermediary of a graphite sub-electrode. In this way, a good electrical contact between the friction material and the electrode and a uniform current flow through the material can be obtained.