Golf club head having fast materials and methods for manufacturing

Abstract

A golf club head, comprising: a body having a front defining a front opening, a crown, a sole opposite the crown, a toe, a heel opposite the toes, and a skirt located between the crown and the sole and extending proximate the toe to proximate the heel. A faceplate secured to the front of the body and covering the front opening to form a hollow interior cavity. The faceplate comprises a rear surface, facing the hollow interior cavity, and a striking surface opposite the rear surface. The faceplates further comprise a plurality of grains having a grain structure that is substantially equiaxed and isotropic.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This claims the benefit of prior-filed U.S. Provisional Application No. 63 / 684,078 filed Aug. 16, 2024, the contents of which are fully incorporated herein by reference.TECHNICAL FIELD

[0002] This disclosure generally relates to golf clubs, and more particularly to faceplate materials microstructure.BACKGROUND

[0003] The faceplate of a golf club head is unique in the fact that it is the only portion that repeatedly impacts a golf ball. The reaction forces produced at impact generate transferable energy. At the start of impact, the faceplate contacts the golf ball and starts to deflect rearwardly. Once the faceplate reaches maximum deflection, it starts to return forwardly to its original, undeflected state, converting stored potential energy into kinetic energy that is transferred to the golf ball. Along with increasing the strength and the durability of the golf club head, designers also seek to improve the performance characteristic of the golf club head. Ball speed and the ball's reaction off the faceplate (Characteristic Time (CT)) are effected by the material of the faceplate combined with variable face thickness configuration and overall mass properties of the golf club head. Resulting ball speed greatly depends on the efficiency of energy transfer. Therefore, the faceplate must be elastic enough to deform, regain its original structure after impact, and maintain its characteristic time for the impact zone while being durable enough to withstand repeated impacts.

[0004] Faceplates made from steel and titanium are normally cut from rolled sheets after multiples pressing steps. Even then the faceplate must then be temperature and pressure cured to meet the kinetic and durability requirements for golf. Thus, the faceplate of the golf club head must be made from a material having high strength and durability, yet still deformable at impact to maximize energy transferred to the golf ball. Metal alloys, such as titanium and steel, are high in strength and durability while still being deformable and are therefore commonly used in golf club faceplates and other sporting equipment.

[0005] The chemical composition, quality of materials, and process used to form the titanium alloy all affect the physical characteristics and performance of the faceplate. Traditional forming processes require numerous steps and often result in grain structures that limit the mechanical properties of the faceplate. Additional processing steps in the form of heat treatments must then be applied to attempt to mitigate those limitations, thereby increasing manufacturing time and cost. Prior art faceplates have anisotropic properties of metal crystals, and their strength / elasticity are depending upon roll direction and post processing (heat treatment) as the faceplate is formed (by sheets and cut out). Certain direction of anisotropic structures of steel / iron / titanium creates the required kinetic (deflection) and strength properties, but in the other direction, this structure causes faceplate failure. Therefore, faceplates that have isotropic rather than anisotropic properties are needed to improve faceplates in golf to maximize the kinetic properties in all directions and orientations.BRIEF DESCRIPTION OF DRAWINGS

[0006] To facilitate further description of the embodiments, the following drawings are provided in which:

[0007] FIG. 1 is a perspective view of a golf club head according to the present disclosure.

[0008] FIG. 2 is a perspective view of a golf club head according to the present disclosure.

[0009] FIG. 3 is an exploded perspective view of the golf club head of FIG. 2.

[0010] FIG. 4A is a front elevation view of a faceplate, according to the present invention.

[0011] FIG. 4B is a side elevation view, in cross-section, of a faceplate of FIG. 4A.

[0012] FIG. 5A is a front elevation view of a faceplate, according to the present invention.

[0013] FIG. 5B is a side elevation view, in cross-section, of a faceplate of FIG. 5A.

[0014] FIG. 5C is a side elevation view, in cross-section, of a faceplate according to the present disclosure.

[0015] FIG. 5D is a side elevation view, in cross-section, of a faceplate according to the present disclosure.

[0016] FIG. 6A is a front elevation view of a faceplate, according to the present invention.

[0017] FIG. 6B is a side elevation view, in cross-section, of a faceplate of FIG. 6A.

[0018] FIG. 6C is a side elevation view, in cross-section, of a faceplate according to the present disclosure.

[0019] FIG. 7 is a schematic view of apparatus for performing FAST.

[0020] FIG. 8 is a block diagram of a process for forming a golf club head component using a Field Assisted Sintering Technology.

[0021] FIG. 9 is a scanning electron microscope image depicting the grain structure of a faceplate according to a first example.

[0022] FIG. 10 is a scanning electron microscope image depicting the grain structure of a faceplate according to a second example.

[0023] FIG. 11 is a scanning electron microscope image depicting the grain structure of a faceplate according to a third example.

[0024] FIG. 12 is a scanning electron microscope image depicting the grain structure of a faceplate according to a fourth example.

[0025] FIG. 13 is a scanning electron microscope image depicting the grain structure of a faceplate according to a fifth example.

[0026] FIG. 14 is a scanning electron microscope image depicting the grain structure of a faceplate according to a sixth example.

[0027] FIG. 15A is a scanning electron microscope image depicting the material powder according to the present invention.

[0028] FIG. 15B is a scanning electron microscope image depicting the material powder according to prior art.

[0029] FIG. 15C is a scanning electron microscope image depicting the material powder according to prior art.

[0030] FIG. 16A a scanning electron microscope image depicting the grain structure of a faceplate according to prior art in a longitudinal view.

[0031] FIG. 16B a scanning electron microscope image depicting the grain structure of a faceplate according to prior art in a transverse view.

[0032] FIG. 17A illustrates the grain structure of a faceplate formed from a wrought titanium sheet.

[0033] FIG. 17B illustrates the grain structure of a faceplate formed via FAST.

[0034] FIG. 18A illustrates the equiaxed grain structure of a faceplate formed via FAST.

[0035] FIG. 18B illustrates the grain structure of a faceplate formed from traditional methods prior to rolling.

[0036] FIG. 18C illustrates the grain structure of a faceplate formed from traditional methods post a unidirectional rolling.

[0037] For simplicity and clarity of illustration, the drawing figures illustrate the general manner of construction, and descriptions and details of well-known features and techniques may be omitted to avoid unnecessarily obscuring the invention. Additionally, elements in the drawing figures are not necessarily drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help improve understanding of embodiments of the present invention. The same reference numerals in different figures denote the same elements.Definitions

[0038] The terms “first,”“second,”“third,”“fourth,” and the like in the description and in the claims, if any, are used for distinguishing between similar elements and not necessarily for describing a particular sequential or chronological order. It is to be understood that the terms so used are interchangeable under appropriate circumstances such that the embodiments described herein are, for example, capable of operation in sequences other than those illustrated or otherwise described herein. Furthermore, the terms “include,” and “have,” and any variations thereof, are intended to cover a non-exclusive inclusion, such that a process, method, system, article, device, or apparatus that comprises a list of elements is not necessarily limited to those elements but may include other elements not expressly listed or inherent to such process, method, system, article, device, or apparatus.

[0039] The terms “left,”“right,”“front,”“back,”“top,”“bottom,”“over,”“under,” and the like in the description and in the claims, if any, are used for descriptive purposes and not necessarily for describing permanent relative positions. It is to be understood that the terms so used are interchangeable under appropriate circumstances such that the embodiments of the invention described herein are, for example, capable of operation in other orientations than those illustrated or otherwise described herein.

[0040] An “XYZ” coordinate system of the golf club head, as described herein, is based upon the geometric center of the faceplate. The golf club head dimensions as described herein can be measured based on a coordinate system as defined below. The geometric center of the faceplate defines a coordinate system having an origin located at the geometric center of the face plate. The coordinate system defines an X axis, a Y axis, and a Z axis. The X axis extends through the geometric center of the faceplate in a direction from the heel to the toe of the fairway-type club head. The Y axis extends through the geometric center of the faceplate in a direction from the crown to the sole of golf club head. The Y axis is perpendicular to the X axis. The Z axis extends through the geometric center of the faceplate in a direction from the faceplate to the rear of the golf club head. The Z axis is perpendicular to both the X axis and the Y axis.

[0041] The term “geometric center”, as used herein, refers to the geometric center of the golf club face. The geometric center origin of a coordinate system having an x-axis, a y-axis, and a z-axis. The x-axis extends through the geometric center from near the heel to near the toe of the club head in a direction parallel to a ground plane. The y-axis extends through the geometric center from near the crown to near the sole of the club head in a direction perpendicular to the ground plane. The z-axis extends through the geometric center from the front body portion to the rear body portion of the club head in a direction parallel to the ground plane.

[0042] The term or phrase “center of gravity position” or “CG location” can refer to the location of the club head center of gravity (CG) with respect to the XYZ coordinate system, wherein the CG position is characterized by locations along the X-axis, the Y-axis, and the Z-axis. The term “CGx” can refer to the CG location along the X-axis, measured from the origin point. The term “CG height” can refer to the CG location along the Y-axis, measured from the origin point. The term “CGy” can be synonymous with the CG height. The term “CG depth” can refer to the CG location along the Z-axis, measured from the origin point. The term “CGz” can be synonymous with the CG depth.

[0043] The term or phrase “moment of inertia” (hereafter “MOI”) can refer to a value derived using the center of gravity (CG) location. The MOI can be calculated assuming the club head includes the body and the hosel structure. The term “MOIxx” or “Ixx” can refer to the MOI measured about the X′-axis. The term “MOIyy” or “Iyy” can refer to the MOI measured about the Y′-axis. The term “MOIzz” or “Izz” can refer to the MOI measured about the Z′-axis. The MOI values MOIxx, MOIyy, and MOIzz determine how forgiving the club head is for off-center impacts with a golf ball.

[0044] The term “composition,” as used herein, refers to the kinds and relative count of elements in a material. For alloyed materials, the composition describes the percent of each alloying element within the material.

[0045] The term “a stabilizers” as used herein, is defined as a type of element in a titanium alloy, such as aluminum, oxygen, nitrogen, and carbon. These elements stabilize and strengthen the alpha phase and increase the proportion of alpha phase that can exist at typical ambient temperatures.

[0046] The term “β stabilizers” as used herein, is defined as a type of element in a titanium alloy, such as molybdenum, vanadium, iron, and silicon. These elements stabilize and strengthen the beta phase and increase the proportion of beta phase that can exist at typical ambient temperatures.

[0047] The “modulus of elasticity,” or “Young's Modulus,” as used herein, is the ratio of stress to strain and is the slope (E) of the stress-strain curve in the elastic region. The modulus is used to describe a material's stiffness.

[0048] The term “crystal structure,” as described herein, describes the material on the atomic scale and refers to the manner in which atoms, ions, or molecules are spatially arranged. The crystal structure is the highly ordered, repeating arrangement of atoms in a solid material. These structures are typically crystalline, meaning the atoms are arranged in a three-dimensional pattern that extends throughout the material. Crystal structure is defined in terms of unit cell geometry.

[0049] The term “microstructure,” as described herein, describes the structural features of a material, which can be seen using a microscope, such as grain boundaries and grain structures. The microstructure depicts the size and orientation of the grain structure relative to each other and can depict imperfections such as porosity. These features can seldom be seen with the naked eye.

[0050] The term “grain structure,” as described herein, is defined as a collection of many repeating crystalline structures all oriented in different direction. Features of the grain structure such as grain size, and grain orientation can affect the mechanical properties of the material. The size of the grain can affect the strength of the material; wherein smaller gains are linked to stronger materials.

[0051] The term “grain boundaries,” as described herein, is defined as the planar defects that occur where two grains meet. Grain boundaries disrupt the motion of dislocations throughout the material, caused by a force applied to the material. The more grain boundaries that are impacted by an external force the less deformation the material will undergo.

[0052] The term “grain orientation,” as described herein, is defined as the planar defects that occur where two grains meet.

[0053] The term “yield strength” or “proportional limit,” as used herein, is defined as the point on the stress strain curve wherein the material is loaded in tension to the point of permanent, or plastic deformation, such that the deformation remains when the load has been removed.

[0054] The term “elongation” or “minimum elongation,” as used herein, is a measure of the amount of stretch the material can handle before it starts to permanently deform.

[0055] The term characteristic time “CT,” as used herein, is a measurement used to determine the amount of time, measured in microseconds (μs), that a golf ball contacts the strike face at the moment of impact. The characteristic time is measured by impacting a specific spot on the striking surface several times using a small steel pendulum. The characteristic time measurement is for wood-type club heads such as drivers, fairway woods, or hybrids. A computer program measures the amount of time the steel pendulum contacts the strike face at the moment of impact. CT values were based on the method outlined in the USGA's Procedure for Measuring the Flexibility of a Golf Clubhead. For example, Section 2 of the USGA's Procedure for Measuring the Flexibility of a Golf Clubhead (USGA-TPX3004, Rev. 2.0, Apr. 9, 2019) (the “Protocol For Measuring The Flexibility of A Golf Club Head”).

[0056] The term “joule effect” or “joule heating,” as used herein, refers to the process by which the passage of an electric current through a conductor produces heat.

[0057] The term “powder feedstock,” as used herein, refers to the unprocessed, powder material that is used for the FASR forging process.

[0058] The term “FAST chamber,” as used herein, refers to the cell in which the FAST process is conducted. The chamber comprises two electrodes.

[0059] The term “consolidation,” as used herein, refers to the process of transforming loose metal powders into solid, cohesive masses.

[0060] The term “grade,” as used herein, refers to the specific type of material within a broader category of material. For example, if the broader category refers to titanium alloys, the different grades of titanium alloys include, but are not limited to, Ti 7-4, Ti 6-4, T-9S, T9S+, Jun. 22, 2022, Ti 6-4, 10-2-3, HST-220.

[0061] The term “equiaxed,” as used herein, refers to a grain structure wherein the dimensions in all directions are roughly equal. Essentially, the grains are approximately equidimensional, having similar lengths, widths, and heights, giving them a roughly spherical or polygonal shape.

[0062] The term “anisotropic,” as used herein, refers to the mechanical properties of the faceplate having different values when measured in different directions.

[0063] The term “isotropic,” as used herein, refers to the mechanical properties of the faceplate being approximately the same in all directions.

[0064] “Driver golf club heads” as used herein comprise a loft angle less than approximately 16 degrees, less than approximately 15 degrees, less than approximately 14 degrees, less than approximately 13 degrees, less than approximately 12 degrees, less than approximately 11 degrees, or less than approximately 10 degrees. Further, “Driver golf club heads” as used herein comprise a volume greater than approximately 400 cc, greater than approximately 425 cc, greater than approximately 445 cc, greater than approximately 450 cc, greater than approximately 455 cc, greater than approximately 460 cc, greater than approximately 475 cc, greater than approximately 500 cc, greater than approximately 525 cc, greater than approximately 550 cc, greater than approximately 575 cc, greater than approximately 600 cc, greater than approximately 625 cc, greater than approximately 650 cc, greater than approximately 675 cc, or greater than approximately 700 cc. In other embodiments, the volume of drivers can be approximately 400 cc-600 cc, 425 cc-500 cc, approximately 500 cc-600 cc, approximately 500 cc-650 cc, approximately 550 cc-700 cc, approximately 600 cc-650 cc, approximately 600 cc-700 cc, or approximately 600 cc-800 cc.

[0065] “Fairway wood golf club heads” as used herein comprise a loft angle of less than approximately 35 degrees, less than approximately 34 degrees, less than approximately 33 degrees, less than approximately 32 degrees, less than approximately 31 degrees, or less than approximately 30 degrees. Further, in other embodiments, the loft angle of fairway woods can be greater than approximately 12 degrees, greater than approximately 13 degrees, greater than approximately 14 degrees, greater than approximately 15 degrees, greater than approximately 16 degrees, greater than approximately 17 degrees, greater than approximately 18 degrees, greater than approximately 19 degrees, or greater than approximately 20 degrees. In other embodiments still, the loft angle of fairway woods can be between 12 degrees and 35 degrees, between 15 degrees and 35 degrees, between 20 degrees and 35 degrees, or between 12 degrees and 30 degrees. Further, “fairway wood golf club heads” as used herein comprise a volume less than approximately 400 cc, less than approximately 375 cc, less than approximately 350 cc, less than approximately 325 cc, less than approximately 300 cc, less than approximately 275 cc, less than approximately 250 cc, less than approximately 225 cc, or less than approximately 200 cc. In other embodiments, the volume of the fairway woods can be approximately 150 cc-200 cc, approximately 150 cc-250 cc, approximately 150 cc-300 cc, approximately 150 cc-350 cc, approximately 150 cc-400 cc, approximately 300 cc-400 cc, approximately 325 cc-400 cc, approximately 350 cc-400 cc, approximately 250 cc-400 cc, approximately 250-350 cc, or approximately 275-375 cc.

[0066] “Hybrid golf club heads” as used herein comprise a loft angle less than approximately 40 degrees, less than approximately 39 degrees, less than approximately 38 degrees, less than approximately 37 degrees, less than approximately 36 degrees, less than approximately 35 degrees, less than approximately 34 degrees, less than approximately 33 degrees, less than approximately 32 degrees, less than approximately 31 degrees, or less than approximately 30 degrees. Further, in other embodiments, the loft angle of hybrids can be greater than approximately 16 degrees, greater than approximately 17 degrees, greater than approximately 18 degrees, greater than approximately 19 degrees, greater than approximately 20 degrees, greater than approximately 21 degrees, greater than approximately 22 degrees, greater than approximately 23 degrees, greater than approximately 24 degrees, or greater than approximately 25 degrees. Further, “hybrid golf club heads” as used herein comprise a volume less than approximately 200 cc, less than approximately 175 cc, less than approximately 150 cc, less than approximately 125 cc, less than approximately 100 cc, or less than approximately 75 cc. In some embodiments, the volume of the hybrid-type club head can be approximately 100 cc-150 cc, approximately 75 cc-150 cc, approximately 100 cc-125 cc, or approximately 75 cc-125 cc.

[0067] Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,”“comprising,” and “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. All weight percent (wt %) numbers described below are a total weight percent.

[0068] The general terms used to describe the material properties associated with the disclosed material are provided below. These definitions are regarded as the industry standard and are provided by the professional society of material scientists and material engineers, ASM International.DETAILED DESCRIPTION

[0069] Described herein are various embodiments of golf club heads having a high strength titanium alloy or steel faceplate having isotropic properties and equiaxed shape grains. In some embodiments, the faceplate is formed via Field Assisted Sintering Technology Forging (hereafter alternatively referred to as “FAST”). FAST yields near net shaped faceplates from a combination of powder consolidation, electric field, heat and uniaxial compression pressure to perform powder consolidation and forging. The faceplates have an isotropic equiaxed grain structure with little to no crystallographic texture providing a tight knit, uniform grain structure eliminating most if not all porosity within the faceplate.

[0070] When formed using FAST, the faceplate is created using a combination of heat and pressure to simultaneously compact powder and apply uniaxial pressures, which results in a near net shape product. The FAST faceplate is formed in a fraction of the time required by conventional processes due to the combination of the consolidation and heating steps. The faceplate microstructure comprises an improved grain structure, greater material uniformity, and better crystalline structure dispersion, when compared to a faceplate formed using traditional methods. For instance, naturally anisotropic materials, such as titanium and steel, can be made isotropic using FAST. Further, FAST reduces the total manufacturing time and the amount of waste created, due to requiring little to no machining for a final product. The little waste that is formed can also be reused by making the waste powder. Therefore, FAST faceplates create additional cost savings as recycled materials, in the form of swarf or chips, can be reused in lieu of metal powder, and subjected to the FAST process.A. GENERAL DESCRIPTION OF GOLF CLUB HEAD

[0071] The invention, as described herein, is directed to multiple embodiments of varying density and types of faceplate material sharing the characteristics of an isotropic equiaxed grain structure with little to no porosity. The golf club head 100, as described herein, can comprise a faceplate 104 and a body 102 secured together to define a substantially closed / hollow interior cavity 118. The club head body 102 comprises a crown 120, a sole 122 opposite the crown 120, a heel 108, a toe 106 opposite the heel 108, and a rear opposite the faceplate 104. The body 102 can further include a skirt or trailing edge located between the adjoining the crown 120 and the sole 122 and extending from near the heel 108 to near the toe 106 of the club head.

[0072] The club head is a wood-type club head such as a driver, fairway wood, or hybrid as described in this disclosure. The body 102 defines an opening 124 in the front of the club head, and the faceplate 104 is positioned within the opening 124 to form the club head 100. The faceplate 104 has a striking surface 112 intended to impact a golf ball, a rear surface 114 opposite the striking surface 112, and a geometric center 10. The rear surface 114 faces the hollow interior cavity 118. In some embodiments, the faceplate 104 can comprise a variable thickness profile.

[0073] The faceplate 104 can comprise a material with higher durability in high stress areas and a material with more elasticity in lower stress areas. In so doing, the thickness of the faceplate measured form the striking surface to the rear surface can be reduced while still maintaining sufficiently. durability and elasticity to achieve the desired performance characteristics.

[0074] The faceplate 104 can comprise a variable thickness profile, such that the faceplate 104 can comprise a maximum thickness and a minimum thickness. The minimum thickness can be between 0.065 inch and 0.100 inch. The minimum thickness can be between 0.065 inch and 0.070 inch, 0.070 inch and 0.075 inch, 0.075 inch and 0.080 inch, 0.080 inch and 0.085 inch, 0.085 inch and 0.090 inch, 0.090 inch 0.095, or 0.095 inch and 0.100 inch. In some embodiments, the minimum thickness can be less than 0.100 inch, less than 0.095 inch, less than 0.090 inch, less than 0.085 inch, or less than 0.080 inch. The maximum thickness can be between 0.100 inch and 0.150 inch. The maximum thickness can be between 0.100 inch and 0.110 inch, 0.110 inch and 0.120 inch, 0.120 inch and 0.130 inch, 0.130 inch and 0.140 inch, or 0.130 inch and 0.140 inch.

[0075] The faceplate 104 further has a faceplate height, measured parallel to a loft plane between a top end of the faceplate perimeter and a bottom end of the faceplate perimeter. The top end of the faceplate perimeter is located near the crown 120 and the bottom end of the face perimeter is located near the sole 112. The face height of the driver can be between 1.25 inches and 4.00 inches. The face height can be between 1.25 inch and 1.50 inch, 1.50 inch and 1.75 inch, 1.75 inch and 2.00 inch, 2.00 inch and 2.25 inch, 2.25 inch and 2.50 inch, 2.50 inch and 2.75 inch, 2.75 inch and 3.00 inch, 3.00 inch and 3.25 inch, 3.25 inch and 3.50 inch, 3.50 inch and 3.75 inch, or 3.75 inch and 4.00 inch.

[0076] An outer edge of the faceplate extends along a perimeter of the striking surface (here after referred to as the faceplate perimeter) and can be defined where the curvature deviates from the bulge and roll of the striking surface. More specifically, the outer edge can extend entirely along a perimeter of the striking surface near the crown, the toe, the sole, and the heel where the curvature deviates from the bulge and roll of the striking surface.

[0077] The geometric center of the faceplate 104 can be located at a geometric midpoint of the face. In one approach, the geometric center can be located in accordance with the definition of a golf governing body such as the United States Golf Association (USGA). For example, the geometric center can be determined in accordance with Section 6.1 of the USGA's Procedure for Measuring the Flexibility of a Golf Clubhead (USGA-TPX3004, Rev. 1.0.0, May 1, 2008) (available at http: / / www.usga.org / equipment / testing / protocols / Procedure-For-Measuring-The-Flexibility-Of-A-Golf-Club-Head / ) (the “Flexibility Procedure”). All of the characteristics above can be controlled and added by FAST to customize high durability areas, thickness profile, faceplate dimensions and curvature directions.B. MATERIALS-CHEMISTRY AND MECHANICAL PROPERTIES

[0078] The FAST process can be used to convert metal powder (hereafter alternatively referred to as “feedstock powder”) into the desired final form, such as a faceplate, using heat and pressure to compact feedstock powder and apply uniaxial pressure in a single step. The resulting faceplate has improved material uniformity and better dispersion of crystalline structure than traditional forging methods, while reducing waste and saving time and cost. Any shape can be formed by this process either via height, length, thickness and variations thereof. The use of power provides control over grain orientation, allowing the bonding of two different materials to form a multi-material faceplate. Specifically, rear faceplate positions and variable thickness zones of various size and material combinations can be forged quickly and consistently via the FAST process.

[0079] The purity of the feed stock powder impacts porosity of the resulting faceplate. Contaminated powder will have a large number of satellites and some particles with irregular morphology, causing incomplete consolidation between powder feedstock particles or entrapped gas inherent in the powder feedstock. The resulting porosity can compromise the mechanical properties of the faceplate.

[0080] A wide distribution of particle sizes advantageously improves packing density. The magnitude of variation in particle size can be quantified with reference to a coefficient of variation. As the powder is roughly spherical, the particle size can be represented by the diameter. The coefficient of variation can refer to the standard deviation of particle size as a percentage of its mean. The faceplates can have a coefficient of variation can be between 65% and 85%. The coefficient of variation between 65% and 70%, 70% and 75%, 75% and 80%, and 80% and 85%.

[0081] The powder can be formed from a variety of different grade titanium alloy, steel alloy, and / or stainless steel alloy. The grade of the material is determined by the total weight percent of α-stabilizer elements, β-stabilizer elements, and neutral elements. All numbers described below regarding weight percent are a total weight percent (wt %). In addition to the chemical composition, the mechanical properties further depend on the mechanical processes applied to the material and the heat treatment applied to the material.

[0082] The grade of titanium alloy can be, but is not limited to, T9S+, 2041, Nippon (N-1), 8-5-2-5, Ti 6-4, Jun. 22, 2022, 5553, 575, DAT 556, Ti 23, Ti 27, 811, 662, 215, 15-2, Jun. 2, 1946, Jun. 2, 1942, 10-2-3, HST 220, Ti 7-4, 2041, and 19C, or any other suitable grade of titanium. The different grade steel alloy can be but is not limited to 1018, 1020, 1025, 1030, 1040, 1050, 1060, 1080, 4130 4140, 8620, 4340, C300, C350, bluesteel, 6150, or any other suitable grade of steel. The different grades of stainless steel can be but are not limited to 302, 304, 316, 431, 410, 415, 440, 17-A, 17-B, 17-C, 15-3, 13-8, 15-5, 15-7, 455, or any other suitable stainless steel. Example 1 below lists properties for some of these materials. In addition to metal powder, other forms of recycled and processed metals can be used, such as metal chips. As discussed in depth below, the ability to use recycled and processed metals, as opposed to metal powders, can decrease the amount of waste generated, the length of the manufacturing process, and the manufacturing cost. This further allows the foundry to use nearly 100% of the supplied metal, cutting down on waste and removing costly waste procedures of left over metal.

[0083] In some embodiments, the faceplate is a multi-material faceplate having two or more different grades of titanium in various combinations of depths, thicknesses, and locations. The combination of multiple materials within a single faceplate allows targeted areas of the faceplate to have different material properties. In some embodiments, a multi-material faceplate can be formed from two or more grades of titanium. The grade of each Ti material can be strategically selected, based on the location within the faceplate, to improve the performance characteristics of the faceplate. Specifically, the grade of Ti material selected for a certain location alters CT and COR, improves strength and durability, and creates discretionary weight from reduced faceplate thickness.

[0084] Similarly, a multi-material faceplate can be formed from two or more grades of steel or iron. The grade of each steel or iron material can be strategically selected, based on the location within the faceplate, to improve the CT of the faceplate. Specifically, the grade of steel or iron material selected for certain locations alters CT and COR, improves strength and durability, and created discretionary mass for reduced thickness.

[0085] Similar again, a multi-material faceplate can be formed from two or more grades of titanium, steel, or iron, or a mixture thereof. For example, one grade would be a titanium grade (i.e., T9S+, Ti 6-4, HST 220) and another grade can be steel or iron (i.e., C300, 17-A, 17-8). Specifically, the grade of each titanium, steel, or iron material selected for certain locations alters CT and COR, improves strength and durability, and created discretionary mass for reduced thickness. The faceplate can be vital to customize ball speed, durability, and CT.1. Titanium and Steel Alloys

[0086] The total weight percents of α-stabilizer elements and β-stabilizer elements influence the mechanical properties of the material, which affects how the grain structure reacts during formation of the faceplate. More specifically, the mechanical properties are influenced by the specific elements it contains, as well as the ratio between the α-stabilizers and the β-stabilizers. The presence of α-stabilizers (e.g., aluminum, oxygen, carbon, nitrogen, and zirconium) encourages the alloy to exist in a phase at ambient temperatures, while the presence of β-stabilizers (e.g., molybdenum, silicon, vanadium, iron, and chromium) encourages the alloy to exist in the β phase at ambient temperatures. The presence of α-stabilizers stabilize and strengthen the alpha phase and increase the proportion of alpha phase that can exist at typical ambient temperatures, while the presence of β-stabilizers stabilize and strengthen the beta phase and increase the proportion of beta phase that can exist at typical ambient temperatures.

[0087] Titanium alloys are generally classified into five main categories depending on the wt % of α-stabilizers and β-stabilizers. Alpha alloys comprise α-stabilizers and, optionally neutral elements, but no β-stabilizers. These alloys are typically high in strength but brittle. Near alpha alloys comprise a low amount of β stabilizing elements, typically, between 1-3 wt % of one or more β-stabilizing element. α-β alloys comprise approximately 10% beta phase at room temperature. In α-β alloys the two phases exist alongside one another, thereby allowing for a broad range of properties. Near beta alloys comprise approximately 10% to 15% beta phase at room temperature. Beta alloys comprise enough beta-stabilizers to retain its beta phase when quenched to room temperature. The faceplate of the present disclosure can be formed from an α-β alloy.

[0088] In some embodiments, the selected grade of titanium can comprise β Ti alloy 2041. β Ti alloy 2041 can have a total weight percent of α-stabilizer aluminum between 3.0 wt % to 5.0 wt %, a total weight percent of β-stabilizer vanadium between 18.0 wt % to 21.0 wt %, and a total weight percent of tin between 0.25 wt % to 2.0 wt %. β Ti alloy 2041 can have a yield strength between 152 ksi to 174 ksi, an ultimate strength between 165 ksi to 190 ksi, an elongation at break between 5% to 9%, and a modulus of elasticity between 15 Mpsi to 21 Mpsi.

[0089] In some embodiments, the selected grade of titanium can comprise α-β Ti alloy 6-22-22. α-β Ti alloy 6-22-22 can have a total weight percent of α-stabilizer aluminum between 5.0 wt % to 7.0 wt %, a total weight percent of tin between 1.0 wt % to 3.0 wt %, a total weight percent of α-stabilizer zirconium between 1.0 wt % to 3.0 wt %, a total weight percent of β-stabilizer molybdenum between 1.0 wt % to 3.0 wt %, and a total weight percent of β-stabilizer chromium between 1.0 wt % to 3.0 wt %. α-β Ti alloy 6-22-22 can have a yield strength between 145 ksi to 195 ksi, an ultimate strength between 155 ksi to 210 ksi, an elongation at break less than or equal to 11.5%, and a modulus of elasticity between 18.5 Mpsi to 25 Mpsi.

[0090] In some embodiments, the selected grade of titanium can comprise α-β Ti alloy Ti 6-4. α-β Ti alloy Ti 6-4 can have a total weight percent of α-stabilizer aluminum between 5.0 wt % to 7.25 wt %, a total weight percent of β-stabilizer vanadium between 3.0 wt % to 5.0 wt %, a total weight percent of β-stabilizer iron less than or equal to 0.6 wt %, a total weight percent of α-stabilizer oxygen less than or equal to 0.4 wt %, a total weight percent of α-stabilizer carbon less than or equal to 0.12 wt %, a total weight percent of α-stabilizer nitrogen less than or equal to 0.1 wt %, a total weight percent of β-stabilizer hydrogen less than or equal to 0.03 wt %, and a total weight percent of α-stabilizer yttrium less than or equal to 0.01 wt %. α-β Ti alloy Ti 6-4 can have a yield strength between 125 ksi to 150 ksi, an ultimate strength between 260 ksi to 280 ksi, an elongation at break less than or equal to 15%, and a modulus of elasticity between 14.5 Mpsi to 20 Mpsi.

[0091] In some embodiments, the selected grade of titanium can comprise β Ti alloy Ti 10-2-3. α-β Ti alloy 10-2-3 can have a total weight percent of α-stabilizer aluminum between 2.0 wt % to 4.0 wt %, a total weight percent of β-stabilizer vanadium between 8.0 wt % to 12.0 wt %, a total weight percent of β-stabilizer iron between 1.0 wt % to 2.8 wt %, a total weight percent of α-stabilizer oxygen less than or equal to 0.2 wt %, a total weight percent of α-stabilizer carbon less than or equal to 0.1 wt %, a total weight percent of α-stabilizer nitrogen less than or equal to 0.1 wt %, and a total weight percent of β-stabilizer hydrogen less than or equal to 0.03 wt %. α-β Ti alloy 10-2-3 can have a yield strength between 160 ksi to 180 ksi, an ultimate strength between 175 ksi to 195 ksi, an elongation at break between 6% to 14%, and a modulus of elasticity between 14 Mpsi to 18 Mpsi.

[0092] In some embodiments, the selected grade of titanium can comprise α-β Ti alloy HST-220. α-β Ti alloy HST-220 can have a total weight percent of α-stabilizer aluminum between 6.5 wt % to 8.5 wt %, a total weight percent of β-stabilizer molybdenum between 1.8 wt % to 3.2 wt %, a total weight percent of β-stabilizer iron less than or equal to 0.35 wt %, a total weight percent of α-stabilizer oxygen less than or equal to 0.2 wt %, a total weight percent of α-stabilizer carbon less than or equal to 0.15 wt %, a total weight percent of α-stabilizer nitrogen less than or equal to 0.1 wt %, a total weight percent of β-stabilizer hydrogen less than or equal to 0.03 wt %, a total weight percent of β-stabilizer chromium between 1.0 wt % to 2.5 wt %, and a total weight percent of β-stabilizer silicon between 0.2 wt % to 0.3 wt %. α-β Ti alloy HST-220 can have a yield strength between 165 ksi to 187 ksi, an ultimate strength between 180 ksi to 220 ksi, an elongation at break between 5% to 14%, and a modulus of elasticity between 20 Mpsi to 35 Mpsi.

[0093] In some embodiments, the selected grade of titanium can comprise β Ti alloy 19C. B Ti alloy 19C can have a total weight percent of α-stabilizer aluminum between 2.5 wt % to 4.5 wt %, a total weight percent of β-stabilizer molybdenum between 3.0 wt % to 4.5 wt %, a total weight percent of β-stabilizer iron less than or equal to 0.35 wt %, a total weight percent of α-stabilizer oxygen less than or equal to 0.18 wt %, a total weight percent of α-stabilizer carbon less than or equal to 0.1 wt %, a total weight percent of α-stabilizer nitrogen less than or equal to 0.06 wt %, a total weight percent of β-stabilizer hydrogen less than or equal to 0.03 wt %, a total weight percent of β-stabilizer chromium between 5.0 wt % to 7.0 wt %, a total weight percent of β-stabilizer vanadium between 7.0 wt % to 9.0 wt %, and a total weight percent of α-stabilizer zirconium between 3.0 wt % to 5.0 wt %. B Ti alloy 19C can have a yield strength between 160 ksi to 180 ksi, an ultimate strength between 170 ksi to 190 ksi, an elongation at break between 5% to 9%, and a modulus of elasticity between 13 Mpsi to 20 Mpsi.

[0094] In some embodiments, the selected grade of steel can comprise a maraging steel alloy known as C350. The composition of C350 can comprise a total weight percent of 18.5 wt % nickel, 9.0 wt % cobalt, 4.8 wt % molybdenum, 0.6 wt % titanium, 0.1 wt % aluminum, 0.1 wt % or less of silicon, 0.1 wt % or less of manganese, 0.03 wt % or less of carbon, 0.01 wt % or less of sulfur, 0.01 wt % or less of phosphorous, 0.01 wt % zirconium, and 0.003 wt % boron. C350 can have a yield strength between 330 ksi to 350 ksi, an ultimate strength of 340 ksi to 360 ksi, and an elongation between 3% and 13%.

[0095] In some embodiments, the selected grade of steel can comprise a maraging steel alloy known as C300. The composition of C350 can comprise a total weight percent of 18.5 wt % nickel, 12.0 wt % cobalt, 4.8 wt % molybdenum, 1.4 wt % titanium, 0.1 wt % aluminum, 0.1 wt % or less of silicon, 0.1 wt % or less of manganese, 0.03 wt % or less of carbon, 0.01 wt % or less of sulfur, 0.01 wt % or less of phosphorous, 0.01 wt % zirconium, and 0.003 wt % boron. C300 can have a solvus temperature of 760° C., a yield strength between 265 ksi to 300 ksi, an ultimate strength of 283 ksi to 305 ksi, an elongation between 4% and 7%, and an elasticity between 23.5 Mpsi and 26.0 Mpsi.

[0096] In some embodiments, the selected grade of steel can comprise a stainless steel alloy known as 17-4. The composition of 17-4 can comprise a total weight percent of 3.0 wt % to 5.0 wt % nickel, 1.0 wt % or less of silicon, 1.0 wt % or less of manganese, 0.07 wt % carbon, 0.4 wt % or less of phosphorous, 15.0 wt % to 17.5 wt % chromium, 3.0 wt % to 5.0 wt % copper, 0.45 wt % tantalum, 0.45 wt % niobium, and 0.03 wt % sulfur. 17-4 can have a solvus temperature of 1,040° C., a yield strength between 165 ksi to 170 ksi, an ultimate strength of 185 ksi to 190 ksi, an elongation between 6% and 10%, and an elasticity between 38 Mpsi and 44 Mpsi.C. MICROSTRUCTURE

[0097] The faceplate of the present invention comprises a uniformly random crystal structure and an equiaxed grain structure. Further, the faceplate is isotropic, such that the mechanical properties of the faceplate are equal in all directions. Titanium, iron, and steel are traditionally anisotropic due to the necessary step of rolling the material to achieve the desired shape, making the mechanical properties weaker in the direction the material is rolled. The faceplates of the present invention overcome these limitations.

[0098] The desired faceplate microstructure can be formed using the FAST process, which consolidates and melts the feedstock in single step, creating a unique structure unattainable by traditional methods. FAST provides a faceplate with a crystal structure that has a mixture of strong and weak planes such, the crystal structure lacks banding and texture. In particular, the resulting crystal structure has a well dispersed mixture of the 12 different crystal orientations (i.e., Basal, prismatic, 1st order pyramidal, 2nd order pyramidal), limiting the formation and propagation of cracks caused by repetitive impact forces. It can be beneficial to have a surplus in 1st or 2nd order pyramidal as they promote durability. The crystal structure is a mixture of strong and weak planes, as such, the crystal structure lacks banding. This ensures little to no macro-zones. Macro-zones help propagate stress, fine line cracks and the overall failure of the faceplate, often at an insufficient number of golf ball impacts

[0099] The faceplate further comprises a grain structure having a plurality of grains. Each grain can comprise a maximum grain size and a minimum grain size. These measurements can be taken when the grain structure can be viewed in 2D similar to that depicted in FIGS. 9-14. The maximum grain size can be defined as the largest distance from one point on the grain's perimeter to another point on the grain's perimeter. The maximum grain size can be defined as the smallest distance from one point on the grain's perimeter to another point on the grain's perimeter.

[0100] The faceplate in the embodiments below have grains that are equalized in shape. The grain structure can comprise an average maximum grain size, defined as the average of all the maximum grain size in a designated sample area. In some embodiments, the average maximum grain size can be less than 15 microns, less than 14 microns, less than 13 microns, less than 12 microns, less than 11 microns, less than 10 microns, less than 9 microns, less than 8 microns, less than 7 microns, less than 6 microns, less than 5 microns, less than 4 microns, less than 3 microns, or less than 2 microns.

[0101] The grain structure can comprise an average minimum grain size, defined as the average of all the minimum grain sizes in a designated sample area. In some embodiments, the average minimum grain size can be less than 10 microns, less than 9 microns, less than 8 microns, less than 7 microns, less than 6 microns, less than 5 microns, less than 4 microns, less than 3 microns, or less than 2 microns.

[0102] The faceplate can further comprise a grain size ratio, defined as the ratio between the average maximum grain size and the average minimum grain size. The grain size ratio can be between 0.75 and 1.00. The grain size ratio can be between 0.75 and 0.80, 0.80 and 0.85, 0.85 and 0.90, 0.90 and 0.95, or 0.95 and 1.00. A grain size ratio of 1.00 is considered to be a homogeneous distribution of grain size. A faceplate having a homogeneous distribution of grain size has highly desirable mechanical properties. In other words, the faceplate, as described herein, comprises grains that are equiaxed in shape (i.e., the dimensions of the grain structure are roughly equal in all direction). Traditionally, post formation manufacturing processes such as heat treatments or recrystallization (by means of cold working) must be employed to try and achieve equiaxed grains. The FAST process, however, yields an equiaxed grain structure without the need for post formation manufacturing processes (i.e., heat treatments). The aforementioned grain structure ensures little to no porosity on the faceplate. In some embodiments, the porosity may be less than 3%. In other embodiments the porosity may be less than 2%, less than 1%, less than 0.5%, or less than 0.1%. The saving of process steps results in a consistent faceplate having isotropic properties rather than guaranteed anisotropic properties by the traditional method of rolling / heat treating faceplates.D. MATERIAL ARRANGEMENTS

[0103] The faceplate has an isotropic, equiaxed grain structure with little to no crystallographic texture. In some embodiments, the FAST process is used to combine heat and pressure in a single step to form a near net shape faceplate. FAST can also be used to yield a faceplate formed from at least two materials in the same single step process. The ability to control the grain orientation of each material reduces strain as result of in-situ densification allowing the bonding of two different materials, forming a multi-material faceplate. The faceplate can comprise two materials that are dissimilar in different regions of faceplate to manipulate CT. Different materials can be strategically placed in different regions of the faceplate to achieve desired mechanical properties in said regions. For example, a faceplate can be made to focus a higher modulus material in regions of the club face that traditionally have higher CT values. A higher modulus material in these regions could reduce the CT value, ensuring the entirety of the faceplate conforms to USGA CT regulations. Conversely, a lower modulus material may be placed in a region in regions of the club face that traditionally have lower CT values, which will aid in increasing CT. The placement of dissimilar materials can optimize CT and COR, improve strength and durability, and reduce the thickness of the faceplate, thereby creating additional discretionary weight.

[0104] In contrast, faceplates formed by traditional processes, such as rolling and heat treatment are anisotropic. Faceplates according to the present invention however have an isotropic equiaxed grain structure with little to no crystallographic texture and porosity and can further have two dissimilar materials without additional joining means, such as welding, brazing, soldering, or a mechanical fastener.

[0105] As shown in FIG. 4A-4B, the faceplate can be formed entirely from a single grade of material selected from the grades of Ti, steel, or iron mentioned above. Alternatively, the faceplate can be formed from two or more different grades of material. Referring to FIG. 5A-5D, in one embodiment, the striking surface can be formed from a grade 1 material, while a grade 2 material forms the rear surface of faceplate. The grade 1 material can comprise a first thickness and the grade 2 material can comprise a second thickness. As shown in FIG. 5B, the first thickness can equal the second thickness. As shown in FIG. 5C, the first thickness can be less than the second thickness. As shown in FIG. 5D, the first thickness can be greater than the second thickness.

[0106] As shown in FIG. 6A-6C one or more materials can be arranged to form the faceplate. As shown specifically in FIG. 6A, a grade 1 material can be arranged in the center of the face surrounded by grade 2 material. The grade 1 material can make up the entirety of the central region and the remainder of the faceplate (i.e., the periphery region) can be made of the grade 2 material.

[0107] As shown in FIG. 6B, the entirety of the central region can be made of the grade 1 material, such that it extends uninterrupted from the striking face to the back surface. Further the entirety of the periphery region can be made of the grade 2 material, such that it extends uninterrupted from the striking face to the back surface.

[0108] In another embodiment, as shown in FIG. 6C, the striking surface of the central region can be made of a first grade 1 material and the back surface of the central region can be made of a second grade 1 material. Further, the entirety of the periphery region can be made of the grade 2 material, such that it extends uninterrupted from the striking face to the back surface.

[0109] In some embodiments, the grade 1 material can be arranged to make up at least 25%, at least 30%, at least 35%, at least 40%, at least 45%, at least 50%, at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, or at least 95% of the faceplate. In some embodiments, the grade 2 material can be arranged to make up at least 25%, at least 30%, at least 35%, at least 40%, at least 45%, at least 50%, at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, or at least 95% of the faceplate.

[0110] In some embodiments, the grade 1 material can be arranged to make up to 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, 100%, 250%, 200%, 250%, 300%, 350%, 400%, 450%, 500%, 550%, 600%, 650%, 700%, 750%, 800%, 850%, or 900% more of the faceplate than the grade 2 material. In some embodiments, the grade 2 material can be arranged to make up to 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, 100%, 250%, 200%, 250%, 300%, 350%, 400%, 450%, 500%, 550%, 600%, 650%, 700%, 750%, 800%, 850%, or 900% more of the faceplate than the grade 1 material. The grades of material discussed in the above embodiments can be any one of the titanium, iron, steel, as mentioned above, or a combination thereof.E. FAST PROCESS

[0111] The FAST process can be used to form faceplates having an isotropic, equiaxed grain structure with little to no crystallographic texture, as well as a tight knit, uniform grain structure that eliminates most, if not all, of the porosity within its micron texture profile. FAST combines heat and pressure in a single step to yield a near net-shaped faceplate in a fraction of the time while reducing manufacturing costs.

[0112] For example, faceplate material properties can be enhanced by the FAST method. The FAST method, schematically illustrated, in FIG. 6, includes a first step of sieving and weighing powder feedstock. In a second step, a lower half of a graphite tooling is assembled, and a mold is lined with graphite foil. In a third step the powder material is placed into the lower half of the graphite tooling. In a fourth step, a top half of the graphite tooling is assembled. In a fifth step, a graphite mold assembly is pre-pressed prior to placement within the FAST chamber. In a sixth step, the graphite mold assembly is placed into the FAST chamber, positioning the mold between two electrodes. In a seventh step, a minimal contact force is applied to the assembly. In an eighth step, a pre-programmed heat and pressure is applied to the assembly. In a ninth step, the mold assembly is removed from the chamber. In a tenth step, the faceplate is pressed out of the tooling assembly using a hydraulic press.

[0113] More specifically, the first step can involve sieving and weighing out the powder prior to placement into the mold assembly. Sieving breaks up any clumping that may be present in the powder and separates the powder based on particle size, allowing the powder to be sufficiently packed to a desired packing density. The packing density is improved by calculating and creating a desired particle distribution, wherein smaller particles reside between larger particles. Greater packing density creates a faceplate with minimal dimension variation, ensuring uniform durability across the faceplate. Fast achieves a faceplate having 99.9% densification, which is equivalent to sheet product.

[0114] The second step involves assembling the lower half of the graphite tooling and lining the mold with graphite foil. Graphite can conduct electricity, and therefore efficiently transfers heat produced by the electrodes to the powder. Additionally, graphite foil can be positioned between the tools and the powder to ensure the powder does not stick to the tools. Once the graphite lining is in place, the third step of placing the powder within the mold, in the desired arrangement, can be performed.

[0115] Following the placement of the powder, the upper half of the tooling assembly can be placed on the lower half of the tooling assembly to create the full tooling assembly in the fourth step. After the tooling assembly is constructed, a pre-press procedure is performed in the fifth step. This pre-press procedure removes excess air from the powder and mold, prepares the powder for further compression, and compacts the tooling assembly to fit within the FAST machine. The upper and lower half comprise the upper and lower rams, that apply pressure to the powder within the molds. The pre-press procedure utilizes a pressure between 0 and 5 MPa. In some instances, the pressure may be between 0 and 1 MPa, between 1 and 2 MPa, between 2 and 3 MPa, between 3 and 4 MPa, or between 4 and 5 MPa.

[0116] Once the pre-press procedure concludes, the tooling assembly is placed in the FAST machine in the sixth step. The FAST machine comprises two electrodes, between which the tooling assembly is placed. One electrode is at the top of the machine and contacts the upper half of the tooling assembly, while the other electrode is at the bottom of the machine and contacts the lower half of the tooling assembly. In the seventh step, the FAST machine first applies a minimum force to bring the electrodes in contact with the tooling assembly. Additionally, the minimal contact force slowly presses the powder, preventing the powder from being pushed up the walls of the mold and keeping the powder in the correct position.

[0117] Following insertion of the tooling assembly into the FAST machine and applying an initial minimum contact force, the machine can begin the pre-programmed operation in the eighth step. The FAST machine is pre-set to achieve a desired temperature and pressure profile. Heating the powder is accomplished through the joule effect. Heat is generated by applying a direct current to the electrodes. Electric energy is converted into thermal energy as a pulsed direct electric current flow through a conductive material, such as graphite. In addition to the heat application, pressure is applied from a hydraulic press. The hydraulic press applies an even amount of uniaxial pressure across the powder to improve the consolidation speed of the material. The combination of heat and pressure in the FAST process consolidates the powder to near net shaped components.

[0118] The heat applied within the FAST machine (hereafter alternatively referred to as “the dwell temperature”) can range from 800° C. to 1500° C. and is monitored with a pyrometer. In some instances, the dwell temperature may be between 800° C. and 850° C., between 850° C. and 900° C., 900° C. and 950° C., between 950° C. and 1000° C., between 1000° C. and 1050° C., between 1050° C. and 1100° C., between 1100° C. and 1150° C., between 1150° C. and 1200° C., between 1200° C. and 1250° C., between 1250° C. and 1300° C., between 1300° C. and 1350° C., between 1350° C. and 1400° C., between 1400° C. and 1450° C., between 1450° C. and 1500° C. The dwell temperature can be below the solvus temperature of the faceplate material. As shown below in Example 2, the dwell temperature greatly affects the porosity of the faceplate.

[0119] The FAST machine can heat up at a rate of 5 to 200° C. / min. In some cases, the heating rate can be between 5 and 20° C. / min, between 2° and 35° C. / min, between 35 and 50° C. / min, between 5° and 65° C. / min, between 65 and 80° C. / min, between 8° and 95° C. / min, between 95 and 110° C. / min, between 11° and 125° C. / min, between 125 and 140° C. / min, between 14° and 155° C. / min, between 155 and 170° C. / min, between 17° and 185° C. / min, or between 185 and 200° C. / min. The chamber initially heats at a rate between 25 to 150° C. / min. In some instances, the heating rate is between 25 and 50° C. / min, between 5° and 75° C. / min, between 75 and 100° C. / min, between 10° and 125° C. / min, or between 125 and 150° C. / min. As the chamber approaches the dwell temperature, the heating rate can be reduced to between 25 and 75° C. / min. In some cases, the heating rate can be reduced to between 25 and 35° C. / min, between 35 and 45° C. / min, between 45 and 55° C. / min, between 55 and 65° C. / min, or between 65 and 75° C. / min. The reduction of the heating rate ensures that excess heat is not applied to the tooling assembly.

[0120] The FAST machine can be held at the dwell temperature for a predetermined amount of time (hereafter alternately referred to as “the dwell time”) The predetermined amount of time can be between 15 minutes and 50 minutes. The predetermined amount of time can be between 15 minutes and 20 minutes, 20 minutes and 25 minutes, 25 minutes and 30 minutes, 30 minutes and 35 minutes, 35 minutes and 40 minutes, 40 minutes and 45 minutes, and between 45 minutes and 50 minutes. The predetermined amount of time can be approximately 15 minutes, 16 minutes, 17 minutes, 18 minutes, 19 minutes, 20 minutes, 21 minutes, 22 minutes, 23 minutes, 24 minutes, 25 minutes, 26 minutes, 27 minutes, 28 minutes, 29 minutes, 30 minutes, 31 minutes, 32 minutes, 33 minutes, 34 minutes, 35 minutes, 36 minutes, 37 minutes, 38 minutes, 39 minutes, 40 minutes, 41 minutes, 42 minutes, 43 minutes, 44 minutes, 45 minutes, 46 minutes, 47 minutes, 48 minutes, 49 minutes, or 50 minutes. In one exemplary embodiment the FAST machine can be held at the dwell temperature for 40 minutes. Similar to the dwell temperature, the dwell time can directly affect the grain structure and more specifically the porosity of the faceplate.

[0121] The pressure applied within the FAST machine can range from 5 to 50 MPa. In some instances, the pressure may range between 5 and 10 MPa, between 10 and 15 MPa, between 15 and 20 MPa, between 20 and 25 MPa, between 25 and 30 MPa, between 30 and 35 MPa, between 35 and 40 MPa, between 40 and 45 MPa, or between 45 and 50 MPa. The pressure is applied variably throughout the process, wherein different stages have higher and lower pressures. Generally, the maximum pressure is applied during the heating stage.

[0122] Following the cessation of the pre-programmed FAST process, the powder is transformed into a solid metal component. Once the tooling assembly cools enough to be handled, it can be removed from the FAST machine in the ninth step. The faceplate can then be pressed out of the mold using a hydraulic press in the tenth step. The hydraulic press is utilized to dismantle the tooling assembly, thereby providing access to the faceplate. The mold provides a faceplate comprising a shape near the shape of the desired finished product. Specifically, the faceplate can be FAST forged to have the desired thickness, shape, and bulge and roll straight from the machine. Minimum machining and / or finishing is required to obtain a final product.F. ALTERNATIVE ADDITIVE POWDER-BASED MANUFACTURING PROCESSES

[0123] Alternative additive powder-based manufacturing processes can be applied to achieve the material arrangements discussed above. Alternative additive powder-based manufacturing processes can include but are not limited to, 3-D printing, hot isostatic pressing, general sintering, cold isostatic consolidation, shock consolidation, powder forging, and any combination thereof. In one embodiment a combination of powder forging (dry pressing), and uniaxial pressing is used to achieve the material arrangements discussed above.G. BENEFITS OF ADDITIVE POWDER BASED MANUFACTURING PROCESSES

[0124] Additive powder-based manufacturing processes (such as FAST) provide advantages over traditional faceplate forming methods, such as rolling and heat treatments. For example, additive powder-based manufacturing processes can produce equiaxed, isotropic grain structure, which provide consistent mechanical properties in all directions. This removes the dependency of orientation when creating and fitting a faceplate to a golf club head. Conversely, using a traditional rolling procedure results in an anisotropic grain structure, which has varying mechanical properties depending on if it is evaluated with the grain direction or across the grain direction. Therefore, the traditional rolling procedure produces a less consistent product, wherein faceplates must be cut and oriented in a way where the desired mechanical properties are properly aligned to withstand the stresses of a golf ball strike. Additionally, additive powder-based manufacturing processes create near net shaped parts that require minimal post processing, thereby reducing the amount of steps and time it takes to produce a final product. Traditional rolling methods require numerous individual steps (rolling, cutting, machining, heat treating, etc.) to produce a final product. In conclusion, additive powder-based manufacturing processes produce a more consistent product compared to traditional rolling processes, which is attributed to its equiaxed, isotropic microstructure. Further, additive powder-based manufacturing processes can produce faceplates faster than traditionally rolled faceplates because the process creates near net shaped components.H. EXAMPLES1. Example 1

[0125] Faceplates of the present invention were made of various titanium, steel, and iron grades. These grades and chemistries are presented in the tables below.TABLE 1Titanium AlloysTi 6-4T9S+Ti 6-22-22HST - 220Aluminum (wt %) 5.0-7.25 7.0-13.03.0-5.06.5-8.5Vanadium (wt %)3.0-5.01.5-7.018.0-21.00.5-1.1Molybdenum (wt %)—0.2-1.01.0-3.01.8-3.2Iron (wt %)≤0.6≤0.4—≤0.2Oxygen (wt %)≤0.4≤0.15≤0.14≤0.15Silicon (wt %)—0.05-0.350.20-0.300.2-0.3Carbon (wt %)≤0.12≤0.1≤0.05≤0.15Nitrogen (wt %)≤0.1≤0.05≤0.03≤0.1Hydrogen (wt %)≤0.03—≤0.0125≤0.03Yttrium (wt %)≤0.01———Tin (wt %)——1.0-3.0—Zirconium (wt %)——1.0-3.0—Chromium——1.0-3.01.0-2.5Solvus Temperature 980-10001000 700-1000890(° C.)Yield Strength (ksi)125-150136145-195165-187Ultimate Strength260-280144155-210180-220(ksi)Elongation (%)≤158≤11.5 5-14Elasticity (Mpsi)14.5-20  —18.5-25  20-35TABLE 2SteelC350C30017-4Nickel (wt %)18.518.53.0-5.0Cobalt (wt %)9.0012.00—Molybdenum (wt %)4.804.80—Titanium (wt %)0.601.40—Aluminum (wt %)0.100.10—Silicon (wt %)≤0.10≤0.10≤1.0Manganese (wt %)≤0.10≤0.10≤1.0Carbon (wt %)≤0.03≤0.030.070Sulfur (wt %)≤0.01≤0.010.030Phosphorus (wt %)≤0.01≤0.01≤0.40Zirconium (wt %)0.010.01—Boron (wt %)0.0030.003—Chromium (wt %)——15.0-17.5Copper (wt %)——3.0-5.0Tantalum (wt %)——0.45Niobium (wt %)——0.45Solvus Temperature—7601040(° C.)Yield Strength (ksi)330-350265-300165-170Ultimate Strength340-360283-305185-190(ksi)Elongation (%) 3-134-7 6-10Elasticity (Mpsi)—23.5-26.038-442. Example 2Single material faceplates were constructed via a FAST process under varying conditions to compare the effects on the grain structure of the faceplate depending upon dwell time and dwell temperature. In this test, only dwell time and dwell temperature were varied over six Ti (T9S+) faceplate samples to understand the effect on grain structure and mechanical properties of the resultant faceplates. A titanium alloy (T9S+) powder was used to create each of the six exemplary T9S+ faceplates.a. Faceplate 1T9S+ powder was loaded into a faceplate mold and placed within a FAST machine to form faceplate 1. The FAST process was run utilizing a dwell temperature of 1,100° C. and a dwell time of 30 minutes. This dwell temperature and time resulted in a faceplate with a grain structure as seen in FIG. 9. Faceplate 1 achieved full consolidation resulting in large beta grains 304 and lamellar alpha microstructures 302. Ideally, the T9S+ faceplates are processed below the beta region, to achieve an equiaxed alpha microstructure. The grain structure of faceplate 1 showed that forming the faceplate at a dwell temperature of 1,100° C. for 30 minutes was too hot for too long to achieve the desired equalized grain structure for golf faceplates.b. Faceplate 2To form faceplate 2, T9S+ powder was again loaded into a faceplate mold and placed within a FAST machine. In this test, the dwell temperature was reduced to 950° C. (from 1,100° C.) with a dwell time of 5 minutes (from 30 minutes) resulting in the grain structure seen in FIG. 10. The grain structure achieved at this temperature and time is significantly different than faceplate 1 because it was processed below the beta region. This resulted in faceplate 2 having a semi-equiaxed alpha microstructure, but lacking full consolidation, noticeable in the form of unconsolidated regions (porosity 312). Porosity refers to the holes within the grain structure of the metal and compromises the mechanical properties of the faceplate. For instance, these holes provide weak points and allow cracks to more easily propagate throughout the material, as the crack grown from one porous region to another. Ideally, a tight grain pattern with full consolidation will result in the most durable sample. The presence of porosity 312 is a sign that the dwell time should be increased. The formation of the second faceplate proved it beneficial for the dwell temperature to below the solvus temperature, in the case of T9S+. For the remainder of this test the dwell temperature was held at 950° C. and the dwell time was varied.c. Faceplate 3To form faceplate 3, T9S+ powder was loaded into a faceplate mold and placed within a FAST machine. In this test, the dwell temperature was set to 950° C. with a slightly increased dwell time of 10 minutes to achieve better consolidation. This dwell time and temperature combination resulted in the grain structure seen in FIG. 11. The grain structure of faceplate 3 was noticeably different than faceplate 2, having grains that were longer and narrower. This was the result of the temperature exceeding the desired 950° C. target, thereby initiating more beta transformations. This further represents the importance of utilizing the correct dwell temperature to obtain the desired grain structure and mechanical properties. A dwell temperature that is higher than the solvus temperature resulted in a more beta dominant grain structure, as seen in faceplate 1 (FIG. 9) and faceplate 3 (FIG. 11). Faceplate 3 did obtain better consolidation than faceplate 2 due to the increased dwell time. Less porosity is found in the grain structure of faceplate 3, wherein greater than 99.9% consolidation was achieved.d. Faceplate 4T9S+ powder was loaded into a faceplate mold and placed within a FAST machine to form faceplate 4. In this test, the dwell temperature was set to 950° C. with a dwell time of 20 minutes in an attempt to achieve better consolidation and a semi-equiaxed alpha grain structure. This dwell time and temperature resulted in the grain structure seen in FIG. 12. Faceplate 4 achieved a semi-equiaxed alpha grain structure, with nearly full consolidation, thus the porosity 332 regions were nearly eliminated, suggesting a slightly longer dwell time may be more beneficial to achieving a non-porous grain structure. On average, faceplate 4 attained an average grain size of 10.5 microns. Smaller grain sizes are beneficial for durability, as smaller, tighter grain structures reduce the ability of cracks to propagate throughout the sample.e. Faceplate 5T9S+ powder was loaded into a faceplate mold and placed within a FAST machine to form faceplate 5. In this test, the dwell temperature was set to 950° C. with a dwell time of 30 minutes, 10 minutes over Faceplate 4; dwell time of 20 minutes. Faceplate 5 achieved an equiaxed alpha grain structure, as shown in FIG. 13, with full consolidation, thus the porosity regions were eliminated, confirming that a slightly longer dwell time was beneficial to achieving a non-porous grain structure. Additionally, faceplate 5 achieved an average grain size of 12.3 microns. Comparatively, faceplate 5 had the best grain structure between faceplates 1-5, by eliminating porosity and achieving an equiaxed alpha grain structure.f. Faceplate 6T9S+ powder was loaded into a faceplate mold and placed within a FAST machine to form faceplate 6. In this test, the dwell temperature was set to 950° C. with a dwell time of 60 minutes, 30 minutes over Faceplate 4; dwell time of 30 minutes. This dwell time and temperature resulted in the grain structure seen in FIG. 14. Faceplate 6 achieved an equiaxed alpha grain structure, with full consolidation, thus the porosity regions were eliminated, confirming that a slightly longer dwell time was beneficial to achieving a non-porous grain structure. Faceplate 6 achieved a very similar grain structure to faceplate 5, however faceplate 6 did achieve a grain structure with a slightly smaller average grain size. Although the smaller average grain size does yield more desirable mechanical properties, it was determined the improvements in the mechanical properties were not large enough to warrant the increased manufacturing time to incorporate a 60 minute dwell time. Therefore, faceplate 5, after undergoing FAST with a dwell temperature of 950° C. and a dwell time of 30 minutes, had the most desirable mechanical properties in an acceptable manufacturing time.3. Example 3 (Uniformity of Powder)

[0133] Single material faceplates were constructed via a FAST process using two different grade titanium alloys. In this test, the dwell time (30 minutes) and dwell temperature (950° C.) remained constant. A first faceplate was formed using Ti 6-4 powder. The Ti 6-4 powder had the following chemical compositions: a total weight percent of α-stabilizer aluminum between 5.0 wt % to 7.25 wt %, a total weight percent of β-stabilizer vanadium between 3.0 wt % to 5.0 wt %, a total weight percent of β-stabilizer iron less than or equal to 0.6 wt %, a total weight percent of α-stabilizer oxygen less than or equal to 0.4 wt %, a total weight percent of α-stabilizer carbon less than or equal to 0.12 wt %, a total weight percent of α-stabilizer nitrogen less than or equal to 0.1 wt %, a total weight percent of β-stabilizer hydrogen less than or equal to 0.03 wt %, and a total weight percent of α-stabilizer yttrium less than or equal to 0.01 wt %, and a Ti balance.

[0134] A second faceplate was formed using T9S+ powder where the dwell time and dwell temperature were the same as Ti 6-4. The T9S+ powder had the following chemical composition a total weight percent of α-stabilizer aluminum between 7.0 wt % to 13.0 wt %, a total weight percent of β-stabilizer vanadium between 1.5 wt % to 7.0 wt %, a total weight percent of β-stabilizer molybdenum between 0.2 wt % to 1.0 wt %, a total weight percent of α-stabilizer oxygen between 0.05 wt % to 0.35 wt %, a total weight percent of β-stabilizer silicon between 0.01 wt % to 0.10 wt %, and a Ti balance. A direct comparison of the chemical composition of the faceplates can be seen below in Table 3.TABLE 3Chemical Composition ComparisonFaceplate 1Faceplate 2Grade of MaterialTi 6-4T9S+Aluminum 5.0 wt % to 7.25 wt % 7.0 wt % to 13.0 wt %Vanadium3.0 wt % to 5.0 wt %1.5 wt % to 7.0 wt %Molybdenum—0.2 wt % to 1.0 wt %Ironless than or equal to 0.6 wt %—Oxygenless than or equal to 0.4 wt %0.05 wt % to 0.35 wt %Silicon—0.01 wt % to 0.10 wt %Carbonless than or equal to 0.12 wt %—Nitrogenless than or equal to 0.1 wt %—Hydrogenless than or equal to 0.03 wt %—Yttriumless than or equal to 0.01 wt %—TitaniumBalanceBalance

[0135] As shown above in Table 3, Faceplate 1 comprises significantly less aluminum than Faceplate 2 (T9S+). A microscopic depiction of the powder used to form Faceplate 1 can be seen in FIG. 13A. As shown in FIG. 13A, the powder particles of Faceplate 1 are relatively uniform in both size and shape. A microscopic depiction of the particles of the powder used to form faceplate 2 can be seen in FIGS. 13B-13C. As shown in FIGS. 13B-13C, faceplate 2 varies drastically in shape and size. Specifically, the powder comprised a large number of satellites and some particles with irregular morphology. Porosity is due to incomplete consolidation between powder feedstock particles or entrapped gas inherent in the powder feedstock. Porosity can compromise the mechanical properties of the faceplate. The presence of porosity is a sign that the powder is of poor quality. Therefore, it was determined that the porosity and irregularity within the powder particles was due to the powder contamination and chemistry variation.

[0136] One theory is that there was a variation (in the form of clumping due to powder contamination and chemistry variation) in the amount of aluminum in the feedstock used to form the faceplate. Aluminum has a low melting point. When the scrap material was remelted and made into feedstock powder, variation in the amount of aluminum was present. This caused unwanted variations in the local chemistry, faceplate dimensions and ultimately led to durability issues.4. Example 4 (Post Formation Manufacturing Processes)

[0137] Post formation processing of FAST generated faceplates was conducted in this Example. Single material faceplates were constructed via a FAST process. The same exact process was used to create each faceplate. A titanium alloy (T9S+) powder was used to create two exemplary faceplates, a first exemplary faceplate and a second exemplary faceplate. After the first exemplary faceplate was formed via FAST an aging heat treatment was applied at a temperature of 600° C. No post formation manufacturing processes were applied to the second exemplary faceplate. A comparison of the mechanical properties of each faceplate and wrought TS9+ can be seen below in Table 4. Each faceplate was cut in the longitudinal and transvers direction to determine the mechanical properties.TABLE 4Mechanical Property ComparisonYieldTensileStrengthStrengthElongationMod(ksi)(ksi)(%)(MPSI)First exemplary139.2137.23.018.38Faceplate -LongitudinalFirst Exemplary138.8138.73.1418.28Faceplate -TransverseSecond139.2141.63.1418.56ExemplaryFaceplate -LongitudinalSecond138139.8418.5ExemplaryFaceplate -TransverseWrought T9S+1361448—

[0138] As shown above in Table 4, the post formation manufacturing process of aging had little effect on the mechanical properties of the FAST faceplates. Both faceplates comprise equivalent mechanical properties, establishing that the FAST faceplates lack the need for additional post formation manufacturing process, saving both time and money. Further as shown in Table 4, each exemplary faceplate has equivalent mechanical properties in both the transverse and longitudinal direction. The equivalent mechanical properties proved each faceplate was isotopic.5. Example 5 (Wrought Vs. FAST Microstructure)

[0139] It is desirable to have a titanium faceplate that is equiaxed and isotropic, which provides similar mechanical properties in all directions. Generally, titanium faceplates are made from wrought material (rolled sheets) and are naturally anisotropic. This is attributed to the rolling process used to achieve a desired sheet thickness, which inherently changes the microstructure of the sheet by displacing the titanium grain structures in the direction of the temperature and pressure roll. A faceplate was made via rolling and heat treatments for a of T9S+ titanium alloy. The grain structure of the faceplate has a clear directionality, as illustrated in FIG. 17A. The wrought titanium faceplate comprises a grain structure that is noticeably elongated in a horizontal direction, which is also in the rolling direction of the titanium sheet. This anisotropic structure has varying mechanical properties when evaluated in a longitudinal direction (with the grain) and a transverse direction (across the grain).

[0140] As mentioned above, an equiaxed and isotropic grain structure (see FIG. 17B) is desirable as it removes the grain direction effect from the mechanical properties. The faceplate can achieve these properties by FAST. In an equiaxed, isotropic faceplate (T9S+ faceplate sample described in Example 3) there is no discernable grain direction, thus the material is equally strong in all directions. An equiaxed, isotropic faceplate grain structure is illustrated in FIG. 17B. As mentioned, the grain microstructure is such that similar crystallographic orientations do not touch one another. This differs from the wrought example (FIG. 17A), wherein the crystallographic orientations are aligned with the rolling direction. Eliminating / reducing the number of like crystallographic orientations in contact with one another reduces the ability for cracks and stresses to propagate throughout the material. This can be attributed to surrounding grain structures constraining inner grain structures, which makes the material more apt to withstand stress in any direction. For this reason, the equiaxed, isotropic structure, shown in FIG. 17B, is the optimal microstructure. Further, this is achievable through FAST and not through traditional rolling methods, because FAST consolidates the metallic powder at the same time to form a uniform structure. This uniform structure is not further worked to achieve a desired thickness, as is done with wrought product, and which creates anisotropy.

[0141] The mechanical properties of the FAST and wrought T9S+ can be seen below in Table 5. The wrought faceplate clearly has a directional bias, wherein it is stronger in the transverse direction, but has a significantly lower elongation in this orientation. This is due to the transverse direction being across the grain, which inherently is stronger, but is less susceptible to stretching. Conversely, the wrought faceplate has a lower strength in the longitudinal direction but has the ability to stretch.

[0142] While the FAST faceplate may show lower strength values (attributed to contaminated powder), the similarity in yield strength of the two perpendicular directions emphasize the importance of an equiaxed, isotropic microstructure. Specifically, the yield strength, elongation, and modulus are all similar whether evaluating in the longitudinal or transverse direction. Given a pure sample (no contaminants), a faceplate formed via FAST would approximately exhibit the mechanical properties shown below, in Table 5, in any direction.TABLE 5Mechanical Property ComparisonYieldStrengthElongationMod(ksi)(%)(MPSI)Wrought T9S+ -145.014.315.6LongitudinalWrought T9S+ -153.02.819.5TransverseFAST T9S+ -139.23.018.4LongitudinalFAST T9S+ -138.83.1418.3TransversePure T9S+ (All150.0817Directions6. Example 6 (Durability)

[0143] Single material faceplates were constructed via a FAST process and tested for durability. The same exact process was used to create four faceplates. T9S+ powder was loaded into a faceplate mold and placed within a FAST machine to form the faceplate. In this test, the dwell temperature was set to 950° C. with a dwell time of 30 minutes. No additional post formation processes were applied. Each faceplate was welded into an identical driver type golf club head. Each club head underwent a series of impacts with a golf ball. In the test the club head was propelled at a speed of 130 miles per hour. The four club heads on average withstood an average on 794 impacts and one club head withstood 1000 impacts before failure. While these four faceplates did not meet the durability expectations, it is noted that these faceplates had contaminants as discussed in Example 3, and durability is expected to increase exponentially with the elimination of the contaminants.ClausesClause 1: A golf club head, comprising: a body having a front defining a front opening, a crown, a sole opposite the crown, a toe, a heel opposite the toes, and a skirt located between the crown and the sole and extending proximate the toe to proximate the heel; a faceplate secured to the front of the body and covering the front opening to form a hollow interior cavity, comprising: a rear surface, facing the hollow interior cavity, and a striking surface opposite the rear surface; a plurality of grains having a grain structure that is substantially equiaxed and isotropic.

[0145] Clause 2: The golf club head of clause 1, wherein the faceplate comprises a porosity less than 3%.

[0146] Clause 3: The golf club head of clause 1, wherein the faceplate comprises a porosity less than 2%.

[0147] Clause 4: The golf club head of clause 1, wherein the faceplate comprises a porosity less than 1%.

[0148] Clause 5: The golf club head of clause 1, wherein the faceplate comprises a porosity less than 0.5%.

[0149] Clause 6: The golf club head of clause 1, wherein the grain structure comprises an average maximum grain size of less than 15 microns and an average minimum grain size of less than 5 microns.

[0150] Clause 7: The golf club head of clause 1, wherein the grain structure comprises a grain size ratio between 0.75 and 1.00.

[0151] Clause 8: The golf club head of clause 1, wherein the grain structure comprises a grain size ratio between 0.85 and 1.00.

[0152] Clause 9: The golf club head of clause 1, wherein the grain structure comprises a grain size ratio between 0.95 and 1.00.

[0153] Clause 10: The golf club head of clause 1, wherein the faceplate is not heat treated once formed.

[0154] Clause 11: The golf club head of clause 1, wherein the faceplate further comprises a crystal structure having a uniform mixture of crystallographic directions.

[0155] Clause 12: A golf club head, comprising: a body having a front defining a front opening, a crown, a sole opposite the crown, a toe, a heel opposite the toe, and a skirt located between the crown and the sole and extending proximate the toe to proximate the heel; a faceplate secured to the front of the body and covering the front opening to form a hollow interior cavity, comprising: the faceplate comprises: a rear surface, facing the hollow interior cavity, and a striking surface opposite the rear surface; a first metallic material forming the striking surface; a second metallic different from the first metallic surface forming the rear surface; wherein the first metallic material and the second metallic material are metallurgically bonded and each comprises a grain structure that is substantially equiaxed and isotropic.

[0156] Clause 13: The golf club head of clause 12, wherein the first metallic material and the second metallic material are different metals.

[0157] Clause 14: The golf club head of clause 12, wherein the first metallic material is a first titanium alloy.

[0158] Clause 15: The golf club head of clause 14, wherein the second metallic material is a second titanium alloy different from the first titanium alloy.

[0159] Clause 16: The golf club head of clause 12 wherein the first metallic material is a steel alloy.

[0160] Clause 17: The golf club head of clause 16, wherein the second metallic material is a steel alloy.

[0161] Clause 18: The golf club head of clause 12, wherein the first metallic material is a titanium alloy and the second metallic material is a steel alloy.

Claims

1. A golf club head, comprising:a body having a front defining a front opening, a crown, a sole opposite the crown, a toe, a heel opposite the toe, and a skirt located between the crown and the sole and extending proximate the toe to proximate the heel;a faceplate secured to the front of the body and covering the front opening to form a hollow interior cavity, comprising:a rear surface, facing the hollow interior cavity, and a striking surface opposite the rear surface;a plurality of grains having a grain structure that is substantially equiaxed and isotropic.

2. The golf club head of claim 1, wherein the faceplate comprises a porosity less than 3%.

3. The golf club head of claim 1, wherein the faceplate comprises a porosity less than 2%.

4. The golf club head of claim 1, wherein the faceplate comprises a porosity less than 1%.

5. The golf club head of claim 1, wherein the faceplate comprises a porosity less than 0.5%.

6. The golf club head of claim 1, wherein the grain structure comprises an average maximum grain size of less than 15 microns and an average minimum grain size of less than 5 microns.

7. The golf club head of claim 1, wherein the grain structure comprises a grain size ratio between 0.75 and 1.00.

8. The golf club head of claim 1, wherein the grain structure comprises a grain size ratio between 0.85 and 1.00.

9. The golf club head of claim 1, wherein the grain structure comprises a grain size ratio between 0.95 and 1.00.

10. The golf club head of claim 1, wherein the faceplate is not heat treated once formed.

11. The golf club head of claim 1, wherein the faceplate further comprises a crystal structure having a uniform mixture of crystallographic directions.

12. A golf club head, comprising:a body having a front defining a front opening, a crown, a sole opposite the crown, a toe, a heel opposite the toes, and a skirt located between the crown and the sole and extending proximate the toe to proximate the heel;a faceplate secured to the front of the body and covering the front opening to form a hollow interior cavity, comprising:the faceplate comprises:a rear surface, facing the hollow interior cavity, and a striking surface opposite the rear surface;a first metallic material forming the striking surface;a second metallic different from the first metallic surface forming the rear surface;wherein the first metallic material and the second metallic material are metallurgically bonded and each comprises a grain structure that is substantially equiaxed and isotropic.

13. The golf club head of claim 12, wherein the first metallic material and the second metallic material are different metals.

14. The golf club head of claim 12, wherein the first metallic material is a first titanium alloy.

15. The golf club head of claim 14, wherein the second metallic material is a second titanium alloy different from the first titanium alloy.

16. The golf club head of claim 12 wherein the first metallic material is a steel alloy.

17. The golf club head of claim 16, wherein the second metallic material is a steel alloy.

18. The golf club head of claim 12, wherein the first metallic material is a titanium alloy, and the second metallic material is a steel alloy.

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