Abstract: A golf club head of cast metal has a cavity formed in the face portion thereof, this cavity being filled with an alloyed material formed from a blended mixture of metallic, refractory, and polymer powders. The golf club head is preheated before the mixture is placed in the club head cavity. After being installed in the cavity the mixture is heated and compressed by the application of force thereto to form a consolidated face plate for the club head which is adhered to the walls of the cavity by virtue of the adhesive properties of the polymer.

Abstract: A method and apparatus for making an insert for selectively, locally, densifying panels having a honeycomb core and at least one face sheet. At least two narrow, long foil strips are fed from supply rollers through a corrugating device which corrugates at least one of the strips. Preferably, the depth of corrugations vary greatly between adjacent strips. From the corrugating device the strips go to a take up reel which winds the strips into a flat pancake coil. When the desired coil diameter is reached the coil is secured to prevent unwinding and the coil is removed from the reel. The coils are used to replace portions of the honeycomb core to locally improve density, strength and thermal transfer characteristics of the panel.

Abstract: A ring insert for locally reinforcing a panel having a honeycomb core and at least one face sheet. The ring insert has at least two adjacent corrugated foil strips wound with the surface of the strips (and the corrugations) lying substantially perpendicular to the ring axis. The corrugations in adjacent strips have substantially different corrugation curve periods to prevent nesting of the corrugations of one strip into those of the next strip. The strips are bonded together to form a unitary ring. These inserts are adapted to be placed in cut-outs of corresponding shape in a honeycomb core and to be bonded thereto and to the panel face sheets. A method and an apparatus for winding the coil are also disclosed.

Abstract: A high strength, light weight stabilized skin structure having spaced skin sheets and a plurality of hollow metal spheres filling the space between the skins. The spheres and skins are bonded together, resulting in a unitary structure. The spheres typically have outside diameters of from about 0.005 to 0.5 inch, with tall thicknesses of about 0.0005 to 0.005 inch. Spheres of different sizes may be used, with smaller or heavier wall thickness spheres in high load areas, such as insert attachment points, and larger spheres in lightly loaded areas. The spheres preferably have a surface coating of a brazing material and are bonded together and to the skins by furnace brazing.

Abstract: A method of diffusion brazing two or more titanium alloy metal parts, such as sheets, thick sections or a honeycomb core to one or two face sheets, to form a unitary panel. A low melting copper-nickel layer is interposed between the faying surfaces of two parts to be bonded. The layer may be a foil placed between the surfaces or may be a layer plated onto one or both surfaces. The assembly is heated to at least the eutectic melting temperature of the base metal-interlayer eutectic point for a time sufficient to permit effective wetting and diffusion bonding of the surfaces. The assembly is held at the elevated temperature a sufficient additional time so as to allow isothermal solidification to occur. The assembly is then cooled, resulting in a unitary structure. This method is particularly effective with titanium aluminides face sheets and a titanium aluminide or other titanium base honeycomb core and with an interlayer consisting essentially of nickel and copper.

Abstract: Apparatus and method for welding high electrically conductive metal and metal alloys. High thermal and high electrical conductive metals such as, for example copper foil and the like, normally unweldable by resistance welding means due to their physical makeup, can now be welded in a conventional manner by the use of pairs of welding electrodes constructed of molybdenum.