Golf Club Head Assembly Using MIM and Resistance Welding
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Solution Overview
Problem
Existing manufacturing processes for golf club heads, such as investment casting and machining sheet metal, are time-consuming, costly, and generate significant waste, especially when dealing with multi-material designs and intricate thickness patterns, while traditional welding methods are inefficient for compact shapes.
Innovation Solution
The method involves metal injection molding (MIM) to create face components and weights using titanium and stainless steel alloys, followed by electrical resistance welding or brazing to bond components, allowing for intricate designs and reduced material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If investment casting is used to manufacture golf club head parts, then the parts can be produced with complex shapes, but the production time is lengthy and production capacity is limited
Solution Approach 1:
The golf club head is divided into multiple separate components (face cup, body, weighting components) that are manufactured independently using metal injection molding, then assembled through resistance welding. This segmentation allows parallel production of multiple parts, significantly increasing production capacity while maintaining complex geometries in each component.
Solution Approach 2:
The manufacturing process transitions from investment casting to metal injection molding, changing the fundamental process parameters. MIM allows for more flexible wall thickness variations and complex geometries without the draft angle constraints of casting, while the high-speed nature of injection molding dramatically increases production rate.
2Manufacturing precision
If machining sheet metal is used to manufacture golf club head parts, then the parts can be produced with precise dimensions, but significant material waste is generated
Solution Approach 1:
The process changes from subtractive machining to additive metal injection molding. MIM builds parts by depositing metal powder in precise layers according to digital models, achieving dimensional accuracy without removing material. This eliminates waste generation while maintaining the precision required for golf club head components.
Solution Approach 2:
The patent utilizes metal powder mixtures (composites of metal powders and binders) in the injection molding process, allowing for multi-material construction. Different metal powders can be combined to create parts with varying densities and properties in different regions, achieving precise dimensional control and weight distribution without material waste.
3Strength
If traditional welding processes are used to join multi-material components, then the components can be bonded together, but the process requires larger head shapes or post-weld machining
Solution Approach 1:
Traditional mechanical welding processes (TIG, plasma, laser) are replaced with electrical resistance welding. This substitution uses electrical current to generate heat directly at the joint interface through resistance, eliminating the need for large access openings or complex positioning fixtures. The compact resistance welding setup can accommodate small, compact iron head shapes without requiring post-weld machining.
Solution Approach 2:
Electrical resistance welding utilizes rapid phase transition of metal at the joint interface. The concentrated electrical current creates localized melting and immediate solidification, forming strong bonds between components. This phase transition process occurs so rapidly and locally that it doesn't require the larger head shapes or extensive post-processing needed by traditional welding methods.
4Adaptability or versatility
If multi-material designs are implemented in compact player's iron heads, then performance can be enhanced, but traditional welding processes become challenging due to size constraints
Solution Approach 1:
The multi-material golf club head is segmented into distinct components (face cup, body, weighting elements) that can be manufactured separately using optimal materials for each function. Metal injection molding allows each segment to be produced with precise material composition and geometry, then assembled through resistance welding. This segmentation makes multi-material design feasible in compact player's iron shapes while maintaining manufacturing ease.
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
This approach significantly reduces production time and costs, enables multi-material designs with complex thickness patterns, and provides a strong, efficient bond without the need for extensive post-weld machining, enhancing the performance and efficiency of golf club head manufacturing.
Implementation Method 1
electrical resistance welding or brazing
Implementation Method 2
metal injection molding
Data Source
AI summary
A golf club head comprising at least one part manufactured via a metal injection molding process, and attached to another part of the golf club head via electrical resistance welding or electrical resistance brazing, is disclosed herein. The present invention is also directed to a method of making said golf club head, the method comprising the steps of providing a first golf club head part made from a first metal material, metal injection molding a second golf club head part from a second, different metal material, and electrical resistance welding or electrical resistance brazing the second golf club head part to the first golf club head part to form a combined part.