Ultra-High Strength Stainless Alloy Strip for Golf Club Heads
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Solution Overview
Problem
Current stainless steel alloys used in golf club faceplates, such as CUSTOM 455 and 465, do not provide the desired strength levels, and the CUSTOM 475 alloy is expensive and less forgiving in the manufacturing process, while the mismatch in heat treating temperatures between faceplate and club body materials results in suboptimal properties in assembled club heads.
Innovation Solution
A stainless steel strip article with a specific corrosion-resistant alloy composition (C0.03 max, Mn1.0 max, Si0.75 max, P0.040 max, S0.020 max, Cr10.9-11.1, Ni10.9-11.1, Mo0.9-1.1, Ti1.5-1.6, Al0.25 max, Nb0.7-0.8, Cu1 max, B0.010 max, N0.030 max, with the balance being iron and usual impurities) is developed, which can be heat treated to achieve a room temperature tensile strength of at least 280 ksi (1930.5 MPa), allowing for double solution treatment without strength loss and compatibility with precipitation hardenable stainless steel club body materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If CUSTOM 455 or 465 stainless steel alloys are used for faceplates, then corrosion resistance is maintained, but tensile strength is insufficient for new club designs
Solution Approach 1:
The patent modifies the chemical composition parameters of the stainless steel alloy by adding specific ranges of titanium (1.5-1.6%), niobium (0.7-0.8%), and controlled amounts of aluminum (0.25 max%) and carbon (0.03 max%). This compositional parameter change enables the material to achieve both high tensile strength (280-320 ksi) and maintained corrosion resistance through the synergistic effect of these alloying elements.
Solution Approach 2:
The invention creates a composite alloy system by combining multiple strengthening elements (Ti, Nb, Al, C) with the base stainless steel matrix. This composite material approach integrates the corrosion resistance of the stainless steel base with the high strength characteristics of the precipitate-forming alloying elements, achieving both required properties simultaneously.
2Strength
If CUSTOM 475 alloy is used to achieve very high strength, then tensile strength increases to 300+ ksi, but manufacturing cost increases and the alloy becomes less forgiving in the manufacturing process
Solution Approach 1:
The patent optimizes the alloy composition parameters to achieve high strength through controlled precipitation hardening rather than excessive alloying. The specific composition ranges (particularly Ti 1.5-1.6%, Nb 0.7-0.8%, and low C 0.03 max%) are designed to provide adequate strength (280-320 ksi) with better manufacturability and re-solutioning capability compared to CUSTOM 475.
Solution Approach 2:
The invention uses a more cost-effective alloy composition that allows for re-solutioning after assembly, replacing the expensive and less forgiving CUSTOM 475 alloy. The material is designed to be economically viable while still achieving the required performance through optimized heat treatment rather than excessive alloy content.
3Manufacturing precision
If faceplate and club body materials have different solution treating temperatures, then each material can be optimized for its specific properties, but the assembled club head provides less than optimum properties after heat treatment
Solution Approach 1:
The patent designs the faceplate alloy to be universally compatible with the club body heat treatment process. The new stainless steel alloy can be solution treated at the same temperature range (1900°F/1038°C) as the precipitation hardenable stainless steel club body, allowing both components to be heat treated together as an assembly to achieve optimal properties in both the faceplate and body simultaneously.
Solution Approach 2:
The invention merges the heat treatment processes for the faceplate and club body into a single unified process. By making the faceplate alloy compatible with the club body's solution treatment temperature, both components can be heat treated together in the assembled configuration, ensuring maximum hardness and strength in both parts without requiring separate heat treatment steps.
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 alloy strip achieves high strength and hardness, reducing manufacturing costs and enabling the faceplate and club body to be solution treated and age hardened in the assembled configuration, ensuring maximum hardness and strength in the golf club head.
Implementation Method 1
The elongated thin strip article provides a room temperature tensile strength of at least 280 ksi (1930.5 MPa) in the solution treated and age hardened condition
Implementation Method 2
heating the elongated strip article at a temperature of 1038-1093°C
Implementation Method 3
heating the elongated strip article at a temperature of 482°C to 510°C
Data Source
AI summary
A stainless steel strip article is disclosed. The article is formed from a corrosion resistant alloy having the following composition in weight percent, C 0.03 max. Mn 1.0 max. Si 0.75 max. P 0.040 max. S 0.020 max. Cr 10.9-11.1 Ni 10.9-11.1 Mo 0.9-1.1 Ti 1.5-1.6 Al 0.25 max. Nb 0.7-0.8 Cu 1 max. B 0.010 max. N 0.030 max. The balance is iron and usual impurities. The elongated thin strip article provides a room temperature tensile strength of at least 280 ksi (1930.5 MPa) in the solution treated and age hardened condition. A method of making the strip article and a method of using it to make a golf club are also disclosed.