Golf club head and a method of manufacture

Abstract

Disclosed is a metal golf club head with optimum macro- and micro-structures and properties and a method for manufacturing a metal golf club head. The method comprises forging precisely a metal billet at a temperature between 35-47% of the melting temperature into a net or near-net lower portion shape comprising a face portion, a hosel portion, and an integrated sole and wall portion. The forging process is preferably performed in at least two stages, with the top stage forging a pre-form shape approximately equal to 60-80% of the final shape. The second stage of the forging process results in the net or near-net shape with only localized conditioning by machining or grinding. A crown portion is manufactured by stamping or forging, and then welded to the lower portion to form the metal golf club head.

1 . A method of manufacturing a metal golf club head, the method comprising the steps of: 
 forging a first portion of the club head including a face portion at a temperature of between 35-47% of the melting temperature of the material in degrees Celsius; and    fabricating a second portion including a crown portion.    
     
     
         2 . The method of  claim 1 , wherein the first portion comprises a face portion, a hosel portion, and an integrated sole and wall portion.  
     
     
         3 . The method of  claim 1 , wherein the first portion comprises a face portion, a hosel portion, and an integrated sole and wall portion, and wherein the weld angle between the second portion and the face portion is 47-55 degrees relative to horizontal, and wherein the weld angle between the second portion and the hosel portion and the integrated sole and wall portion is approximately 45 degrees relative to horizontal.  
     
     
         4 . The method of  claim 1 , further comprising the step of milling the face portion to obtain a thinner face portion.  
     
     
         5 . The method of  claim 1 , wherein the first portion is forged from 10-2-3 Titanium alloy.  
     
     
         6 . The method of  claim 1 , wherein the second portion is a different Titanium alloy.  
     
     
         7 . The method of  claim 1 , wherein the step of forging the first portion further comprises the steps of: 
 heating a first metal billet to approximately 35-47% of the melting temperature of the metal;    forging the first metal billet into a first pre-form shape;    heating the first pre-form shape to approximately 35-47% of the melting temperature of the metal; and    forging the first pre-form shape into a first net or near-net shape of the first portion.    
     
     
         8 . The method of  claim 1 , wherein the step of forging a first portion further comprises the step of: 
 prior to forging the first metal billet into a first pre-form shape, bending the first metal billet into an elbow shape.    
     
     
         9 . The method of  claim 1 , wherein the step of welding is performed without substantial compression.  
     
     
         10 . The method of  claim 8 , further comprising heating the metal billet to approximately 35-40% of the melting temperature of the metal prior to bending.  
     
     
         11 . The method of  claim 1 , wherein the welding is performed by welding the second portion to the first portion at a weld angle of 47-55 degrees relative to horizontal along the face portion, and at a weld angle of approximately 45 degrees relative to horizontal along the integrated sole and wall section.  
     
     
         12 . A method of manufacturing a portion of a metal golf club head, the method comprising the steps of: 
 forging a first metal billet heated to approximately 35-47% of the melting temperature of the metal;    performing the above step at least two times until a net or near-net shape of a first portion is formed from the first metal billet;    forging a second metal billet heated to approximately 35-47% of the melting temperature of the metal until a net or near-net shape of a second portion is formed from the second metal; and    welding the first portion and second portion together.    
     
     
         13 . The method of  claim 12 , wherein the first metal billet and the second metal billet are composed of different alloys.  
     
     
         14 . The method of  claim 12 , further comprising welding the second portion to the first portion at a weld angle of 47-55 degrees relative to horizontal.  
     
     
         15 . The method of  claim 12 , wherein the first portion comprises a face portion, a hosel portion, and an integrated sole and wall portion, and wherein the second portion comprises a crown portion.  
     
     
         16 . The method of  claim 12 , wherein the first portion comprises a face portion, a hosel portion, and an integrated sole and wall portion, wherein the weld angle between the second portion and the face portion is 47-55 degrees relative to horizontal, and wherein the weld angle between the second portion and the hosel portion and the integrated sole and wall portion is approximately 45 degrees relative to horizontal.  
     
     
         17 . The method of  claim 12 , further comprising the step of milling the face portion to obtain a thinner face portion.  
     
     
         18 . The method of  claim 12 , wherein the first portion is forged from 10-2-3 Beta Titanium alloy.  
     
     
         19 . The method of  claim 12 , wherein the second portion is forged from a different Titanium alloy.  
     
     
         20 . A method of manufacturing a metal golf club head, the method comprising the steps of: 
 heating a first metal billet to approximately 35-47% of the melting temperature of the metal;    forging the first metal billet into a first pre-form shape;    heating the first pre-form shape to approximately 35-47% of the melting temperature of the metal;    forging the first pre-form shape into a first net or near-net shape of a first portion having a face portion, a hosel portion, and an integrated sole and wall portion;    fabricating a second portion having at least a crown portion;    placing the first portion on a horizontal plane; and    welding the second portion to the first portion at a weld angle of 47-55 degrees relative to horizontal along the face portion, and at a weld angle of approximately 45 degrees relative to horizontal along the integrated sole and wall section.    
     
     
         21 . The method of  claim 20 , wherein the metal golf club head is a metal wood golf club head with a loft angle from 8-24 degrees.  
     
     
         22 . The method of  claim 20 , wherein the second portion is fabricated by forging a second metal billet heated to approximately 40-47% of the melting temperature of the metal.  
     
     
         23 . The method of  claim 20 , wherein the first metal billet comprises a 10-2-3 Beta Titanium alloy.  
     
     
         24 . The method of  claim 20 , wherein the second portion comprises a different Titanium alloy.  
     
     
         25 . A method of manufacturing a metal golf club head, comprising the steps of: 
 heating a first metal billet to 35-47% of the melting temperature of the metal;    forging the first metal billet into a first pre-form shape;    heating the pre-form shape to 35-47% of the melting temperature of the metal;    forging the pre-form shape into a net or near-net shape substantially equivalent to a lower portion of a base golf club head, the lower portion comprising a face portion, an integrated sole and wall portion, and a hosel portion;    fabricating a second portion having at least a crown portion; and    welding the crown portion to the lower portion.    
     
     
         26 . The method of  claim 25 , wherein the first metal billet comprises a 10-2-3 Titanium alloy and the second portion comprises a different Titanium alloy.  
     
     
         27 . The method of  claim 20 , wherein the step of welding utilizes a 6-4 Titanium alloy welding rod.  
     
     
         28 . The method of  claim 20 , wherein the step of welding is performed at approximately a 50-52 degree angle relative to horizontal along the face portion.  
     
     
         29 . A metal golf club head, comprising: 
 a forged first portion that comprises net or near-net-forged material having, at a forge temperature, a refined macro- and micro microstructure and    a second portion welded to the forged first portion.    
     
     
         30 . The apparatus of  claim 29 , wherein the weld is approximately 47-55 degrees relative to horizontal.  
     
     
         31 . The apparatus of  claim 29 , wherein the first portion comprises a face portion, a hosel portion, and an integrated sole and wall portion.  
     
     
         32 . The apparatus of  claim 29 , wherein the forged first portion and the second portion are composed of different alloys.  
     
     
         33 . The apparatus of  claim 29 , wherein the first portion is welded to the second portion at a weld angle of 47-55 degrees relative to horizontal.  
     
     
         34 . The apparatus of  claim 29 , wherein the first portion comprises a face portion, a hosel portion, and an integrated sole and wall portion, and wherein the second portion comprises a crown portion.  
     
     
         35 . The method of  claim 29 , wherein the first portion comprises a face portion, a hosel portion, and an integrated sole and wall portion, wherein the weld angle between the second portion and the face portion is 47-55 degrees relative to horizontal, and wherein the weld angle between the second portion and the hosel portion and the integrated sole and wall portion is approximately 45 degrees relative to horizontal.  
     
     
         36 . The apparatus of  claim 29 , further comprising the step of milling the face portion to obtain a thinner face portion.  
     
     
         37 . The apparatus of  claim 29 , wherein the first portion is forged from 10-2-3 Beta Titanium alloy.  
     
     
         38 . The apparatus of  claim 29 , wherein the second portion is forged from a different Titanium alloy.  
     
     
         39 . The apparatus of  claim 29 , wherein the first and second portions have been solution heat treated.  
     
     
         40 . The method of  claim 1 , further comprising the step of solution heat treating the golf club head.