Solid-State Joining of Dissimilar Metal Golf Club Components

Solution Overview

Problem

Existing methods for joining metal golf club components, such as TIG, MIG, and laser welding, create intermetallic compounds when melting dissimilar alloys, resulting in weaker joints.

Innovation Solution

Employing solid-state joining processes like linear friction welding, rotational friction welding, diffusion bonding, or ultrasonic welding to join non-cylindrical golf club components made of dissimilar metals without forming intermetallic compounds.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If melting processes (TIG, MIG, laser, plasma welding) are used to join dissimilar metal alloys, then the components can be permanently attached, but intermetallic compounds are created that are weaker and more brittle than the parent materials

Engineering Contradiction:

Improvejoint strengthVSAvoidjoint reliability

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent changes the fundamental parameter of the joining process from melting (liquid state) to solid-state diffusion bonding. By maintaining both materials in the solid state and using diffusion bonding parameters (pressure, temperature below melting point, time), the process avoids intermetallic compound formation while creating strong, reliable joints between dissimilar alloys

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent introduces an interlayer material as a mediator between the dissimilar metal alloys. This interlayer facilitates diffusion bonding by providing a compatible interface that promotes atomic diffusion while preventing direct reaction between the dissimilar base metals, thereby avoiding harmful intermetallic compounds

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If solid state joining processes are used to join dissimilar metal alloys, then intermetallic compounds are avoided and joint strength is maintained, but the process complexity increases compared to conventional welding

Engineering Contradiction:

Improvejoint strengthVSAvoidjoining process complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent replaces the thermal-melting mechanism of conventional welding with a solid-state diffusion mechanism. Instead of using high-energy density heat sources to melt materials, the process uses controlled diffusion bonding with an interlayer, substituting a more complex but controllable solid-state reaction for simpler melting processes

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Produces strong, durable joints between dissimilar metal components without intermetallic compounds, maintaining the strength of the parent materials.

Implementation Method 1

a solid-state joining method is employed. The solid-state joining method may be selected from the group consisting of linear friction welding, rotational friction welding, diffusion bonding, and ultrasonic welding

Methodology Applied

Scientific EffectFriction welding: Friction Welding

Implementation Method 2

a solid-state joining method is employed. The solid-state joining method may be selected from the group consisting of linear friction welding, rotational friction welding, diffusion bonding, and ultrasonic welding

Methodology Applied

Scientific EffectFriction welding: Friction Welding

Implementation Method 3

a solid-state joining method is employed. The solid-state joining method may be selected from the group consisting of linear friction welding, rotational friction welding, diffusion bonding, and ultrasonic welding

Methodology Applied

Scientific EffectDiffusion bonding: Diffusion Welding

Implementation Method 4

a solid-state joining method is employed. The solid-state joining method may be selected from the group consisting of linear friction welding, rotational friction welding, diffusion bonding, and ultrasonic welding

Methodology Applied

Scientific EffectUltrasonic welding: Ultrasonic Vibration

Data Source

PatentUS12357884B1Methods of joining metal golf club components using solid state processes

Publication Date: 2025.07.15 TOPGOLF CALLAWAY BRANDS CORP

AI summary

Methods of joining dissimilar metal, non-cylindrical golf club components, and particularly golf club bodies and faces, using one or more solid state processes are disclosed herein. One method includes the steps of preparing a first non-cylindrical golf club component made of a first metal material, preparing a second non-cylindrical golf club component made of a second metal material that is different from the first metal material, and affixing the first non-cylindrical golf club component to the second non-cylindrical golf club component along a plane using a solid state joining process. Another method includes the steps of providing a golf club body with a first planar joining surface, providing a golf club face component with a second planar joining surface, and affixing the first planar joining surface to the second planar joining surface via linear friction welding, rotational friction welding, diffusion bonding, or ultrasonic welding.