A method of manufacturing a friction element

A method of manufacturing a friction element, the method comprising the steps of:

• providing a back plate, the back plate having a connection surface comprising a plurality of protrusions;
• providing a sintering composition comprising:
• a friction modifying metal in the range of 0 wt % to 5 wt %;
• a fibre component in the range of 1 wt % to 10 wt %;
• metal phosphide in the range of 2.5 wt % to 12 wt %;
• a lubricant in the range of 6 wt % to 23 wt %;
• a filler in the range of 0 wt % to 5 wt %;
• an abrasive in the range of 3 wt % to 20 wt %;
• a processing aid in the range of 0.2 wt % to 2 wt %;
• and
• iron to balance;
• applying the sintering composition to the connection surface and shaping the sintering composition to form an intermediary friction element having a pre sintering puck on the back plate;
• positioning one or more intermediary friction elements between a sintering carrier and a sintering vice plate with the back plate facing the sintering carrier and the pre sintering puck facing the sintering vice plate or with the back plate facing the sintering vice plate and the pre sintering puck facing the sintering carrier;
• and
• simultaneously
• applying a pressure between the sintering vice plate and the sintering carrier, the pressure being in the range of 10 kg/cm2 to 200 kg/cm2;
• increasing the temperature between the sintering vice plate and the sintering carrier to a sintering temperature in the range of 800° C. to 950° C.;
• and
• maintaining at least one of the applied pressure and the sintering temperature for a sintering duration in the range of 1 hour to 10 hours to form a friction material on the back plate.