Golf Club Component Joining With Interlayer Projection Welding

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Solution Overview

Problem

Existing methods for joining dissimilar metal golf club components, such as TIG, MIG, and laser welding, create intermetallic compounds that are weaker than the parent materials, leading to reduced joint strength.

Innovation Solution

Using projection resistance welding with an interlayer material like tungsten, molybdenum, niobium, tantalum, or zirconium to join dissimilar metal golf club components, minimizing liquid state exposure and enhancing joint strength.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional welding methods (TIG, MIG, laser welding) are used to join dissimilar metal golf club components, then the components can be permanently joined, but intermetallic compounds are created that are weaker than the parent materials

Engineering Contradiction:

Improvejoint strengthVSAvoidstrength of intermetallic compounds

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The invention changes the welding parameters by using projection resistance welding instead of traditional fusion welding methods. This process controls the thermal input and bonding conditions to minimize intermetallic compound formation while achieving strong joints between dissimilar metals like stainless steel and aluminum in golf club components.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention introduces an interlayer material as an intermediary between dissimilar metal components during projection resistance welding. This interlayer prevents direct contact and harmful intermetallic compound formation between incompatible metals, while still enabling strong bonding through the projection welding process.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If projection resistance welding is used to join dissimilar metal components, then joint strength is improved, but an interlayer material must be applied which adds manufacturing steps

Engineering Contradiction:

Improvejoint strengthVSAvoidmanufacturing process complexity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The interlayer material is applied in advance to the component surfaces before the projection resistance welding process. This preliminary preparation ensures that the interlayer is in position to prevent intermetallic compound formation during welding, while the subsequent welding process itself remains relatively simple and efficient.

Inventive Principle:

Principle #10Preliminary action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The method achieves joint strength comparable to the parent materials by using projection resistance welding with an interlayer, addressing the weakness of intermetallic compounds formed in traditional welding processes.

Implementation Method 1

projection resistance welding is used to join a golf club face to a golf club body

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

projection resistance welding is used to join a golf club face to a golf club body, a hosel to a golf club body, or another component of a golf club to a golf club body and/or face

Methodology Applied

Scientific EffectDiffusion: Diffusion

Data Source

PatentUS12383807B1Methods of joining metal golf club components with projection resistance welding

Publication Date: 2025.08.12 TOPGOLF CALLAWAY BRANDS CORP

AI summary

A method of joining dissimilar metal, golf club components, and particularly golf club bodies, hosels, and faces, using a projection resistance welding process is disclosed herein. The method may include the step of applying an interlayer material before the projection resistance weld process occurs.