Abstract: A ceramic investment shell mold is reinforced with a carbon based fibrous reinforcement having an extremely high tensile strength that increases as the mold temperature is increased especially within the range of casting temperatures employed for casting large directionally solidified industrial gas turbine components. The carbon based fibrous reinforcement is wrapped or otherwise positioned around the repeating ceramic slurry/stucco layers forming the intermediate thickness of the shell mold wall. The reinforced shell mold can be used to cast large directionally solidified industrial gas turbine components with accurate dimensional control.

Abstract: Concepts for fabricating improved cores for investment casting are described. The cores are composite which include refractory metal elements and ceramic elements. The refractory metal elements are provided to enhance the mechanical properties of the core and/or to permit the fabrication of cores having shapes and geometries that could not otherwise be achieved. In one embodiment, the entire core may be made of refractory metal components. The cores may be used to investment cast gas turbine superalloy components.

Abstract: The strength and solids level of an investment casting shell is increased by incorporating at least one microsilica into the shell.

Abstract: Method and apparatus for providing a plurality of locator elements on a ceramic core involves placing a ceramic core in a die cavity of die, positioning a plurality of pins in the die cavity with each pin having a locator-forming cavity on an inner end facing a surface of the core, and introducing melted wax into each locator-forming cavity to form a plurality of locator elements on the surface of the core.

Abstract: The present invention relates to improvements in and relating to investment casting. In particular, the invention provides a method of investment casting, comprising the steps of mixing a binder, a refractory material, and a quantity of water-insoluble organic fibers to form a slurry; coating an expendable pattern with a coat of said slurry; and drying said coat or allowing said coat to dry to form a shell. The present invention further provides a refractory slurry for use in the method of the invention, and a kit of ingredients for putting the method of the invention into effect.

Abstract: A mold for single crystal casting of molten metallic material is provided having a metallic seed crystal with a passage in an end thereof and an end of a fugitive connector member inserted in the passage. Another end of the connector member is connected to a fugitive pattern. The assembled seed crystal, member, and pattern are invested in a ceramic shell mold so that the mold is invested directly against a side of the seed crystal.

Abstract: A single crystal seed for use in casting a single crystal article, consisting essentially of, in weight %, about 5.0% to about 40.0% Mo, up to 0.1% C and balance essentially Ni.

Abstract: A new mold solves problems that arise from differential changes in geometry inherent to casting metal in a ceramic mold, by control of the internal morphology between the surfaces of the mold that face the casting, and that face the external environment. Layered fabrication techniques are used to create a ceramic mold. For example, an internal geometry composed of a cellular arrangement of voids may be created within the mold wall. Structures may be designed and fabricated so that the ceramic mold fails at an appropriate time during the solidification and/or cooling of the casting. Thus, the casting itself is not damaged. The mold fails to avoid rupture, or even distortion, of the casting.

Abstract: A ceramic casting shell mold having a pre-selected shape comprises alternate, repeating layers of a ceramic coating material and a ceramic stucco, defining a total thickness of the shell mold; and a ceramic-based reinforcing sheet disposed in the alternate, repeating layers of coating material and stucco at an intermediate thickness. The ceramic-based reinforcing sheet comprises a one-piece monolithic, integral body, which comprises a pattern of holes that enhance bonding between the ceramic-based reinforcing sheet and adjacent ones of the alternate, repeating layers of ceramic coating material. The ceramic-based reinforcing sheet conforms to the shape of the mold and providing structural reinforcement to the mold.

Abstract: A ceramic investment shell mold is reinforced with a carbon based fibrous reinforcement having an extremely high tensile strength that increases as the mold temperature is increased especially within the range of casting temperatures employed for casting large directionally solidified industrial gas turbine components. The carbon based fibrous reinforcement is wrapped or otherwise positioned around the repeating ceramic slurry/stucco layers forming the intermediate thickness of the shell mold wall. The reinforced shell mold can be used to cast large directionally solidified industrial gas turbine components with accurate dimensional control.

Abstract: A ceramic investment shell mold is reinforced with a carbon based fibrous reinforcement having an extremely high tensile strength that increases as the mold temperature is increased especially within the range of casting temperatures employed for casting large directionally solidified industrial gas turbine components. The carbon based fibrous reinforcement is wrapped or otherwise positioned around the repeating ceramic slurry/stucco layers forming the intermediate thickness of the shell mold wall. The reinforced shell mold can be used to cast large directionally solidified industrial gas turbine components with accurate dimensional control.

Abstract: Investment shell mold has a locating fixture thereon by which the shell mold can be handled and moved between a mold heating chamber and a casting chamber by a mold manipulator. The mold manipulator positions the preheated mold in the casting chamber to cooperatively engage a locator fixture disposed in the casting chamber. The locator fixture orients the preheated mold in predetermined position relative to a melt-delivery vessel in the casting chamber so as to receive melt therefrom.

Abstract: Method and investment shell mold for casting comprising introducing molten metallic material into an investment shell mold to fill a mold cavity and provide an upper surface of the molten metallic material above the mold cavity. An initially closed, destructible region of the mold then is broken to provide an entry opening through which exothermic material is placed on the upper surface of the molten metallic material to provide a source of molten metallic material to accommodate shrinkage of a casting as it solidifies in the mold cavity.

Abstract: A ceramic casting shell mold having a pre-selected shape is described. It includes alternate, repeating layers of a ceramic coating material and a ceramic stucco, defining a total thickness of the shell mold; and a ceramic-based mat of reinforcing material disposed in the alternate, repeating layers of coating material and stucco. The reinforcing material for the mat is usually made from a ceramic material, and includes fibers having a bi-directional orientation. A method for making a ceramic casting shell mold is also described, as well as articles cast from such a mold, e.g., superalloy articles.

Abstract: A ceramic investment shell mold is reinforced with a carbon based fibrous reinforcement having an extremely high tensile strength that increases as the mold temperature is increased especially within the range of casting temperatures employed for casting large directionally solidified industrial gas turbine components. The carbon based fibrous reinforcement is wrapped or otherwise positioned around the repeating ceramic slurry/stucco layers forming the intermediate thickness of the shell mold wall. The reinforced shell mold can be used to cast large directionally solidified industrial gas turbine components with accurate dimensional control.

Abstract: A new mold solves problems that arise from differential changes in geometry inherent to casting metal in a ceramic mold, by control of the internal morphology between the surfaces of the mold that face the casting, and that face the external environment. Layered fabrication techniques are used to create a ceramic mold. For example, an internal geometry composed of a cellular arrangement of voids may be created within the mold wall. Structures may be designed and fabricated so that the ceramic mold fails at an appropriate time during the solidification and/or cooling of the casting. Thus, the casting itself is not damaged. The mold fails to avoid rupture, or even distortion, of the casting. A thin shell of ceramic defines the casting cavity. This shell must be thin enough to fail due to the stresses induced (primarily compressive) by the metal next to it and partly adherent to it.

Abstract: To form a mold for casting a metal article, metal pins are inserted through a pattern. End portions of the metal pins are bent after the pins have been inserted through the pattern. The pattern and opposite end portions of the metal pins are then covered with wet ceramic mold material. A mold structure is formed by drying the wet ceramic mold material. The pattern is then removed from the mold structure to leave a mold cavity with the metal pins extending through the metal cavity between opposite side sections of the mold structure. Molten metal is conducted into the mold cavity and force is transmitted between opposite side sections of the mold structure through the metal pins to retard movement between the side sections of the mold structure. The molten metal is solidified in the mold cavity and a metallurgical bond is formed between the metal in the mold cavity and the metal pins. The cast article is then removed from the mold structure. The cast article has a thin wall section with a thickness of 0.

Abstract: A method for fabricating a fired ceramic article, a green product, and a fired ceramic article, all for use as a core in the investment casting of directionally solidified eutectic and superalloy material. A ceramic slurry is prepared of alumina, aluminum and a solution of a polymerizable binder in a liquid. The slurry is extruded under low pressure into a closed cavity to form a gelled green product which is subsequently heated in an oxygen-containing atmosphere, wherein the oxygen reacts with the aluminum in the green product to form alumina which advantageously causes an increase in volume of the green product which counters the shrinkage effects of heating.

Abstract: A vent-forming apparatus for use in metal casting comprises a gas-permeable membrane with a lead-in tube attached to one surface and a breather tube attached to the opposite surface. The vent-forming apparatus may be used to create independent vents in the walls of shell-type molds used in the ceramic shell casting process for lost wax casting of ferrous and non-ferrous alloys. These vents exhaust gasses in the mold cavity to the atmosphere. The vent-forming apparatus also may be used in solid mold investment casting methods or in any other casting method in which venting is desirable or necessary.

Abstract: A filter unit for use in metal casting including a filter adapter, a filter adapter per se, and a mold for use in metal casting utilizing the filter unit, as well as a method of producing a metal casting, facilitate or practice direct pouring in a manner which provides for greater flexibility, being applicable to a wider range of castings. The apparatus elements and method are particularly suitable for the manufacturing of castings of relatively high modulus and low pour weight, and for the manufacture of high volume castings of low modulus. The mold includes a mold cavity and a sprue, a filter unit located in the sprue, and the filter unit comprising an adapter of refractory material having one or more ledges o10 for mounting a filter, and a filter (e.g. ceramic foam filter) supported by one of the ledges.

Abstract: This invention relates to a valve apparatus for use in metal casting and methods of its use. The valve apparatus according to this invention comprises a gas-permeable membrane with a lead-in tube attached to one surface and a breather tube attached to the opposite surface. The valve apparatus according to this invention may be used to create independent vents in the walls of shell-type molds used in the ceramic shell casting process for lost wax casting of ferrous and non-ferrous alloys. These vents exhaust gasses in the mold cavity to the atmosphere. The valve apparatus according to this invention also may be used in solid mold investment casting methods or in any other casting method in which venting is desirable or necessary.

Abstract: A process for rapidly forming a ceramic shell mold on an expendable pattern is disclosed. The process entails use of refractory slurries which include a large particle size colloidal silica sol binder. The colloidal silica sol binder has an average particle size of about 40 nanometers, i.e., about 3-4 times larger than colloidal silica sol binders heretofore employed in manufacture of ceramic shell molds. The use of the large particle sols yields unfired ceramic shell molds which have about 40% to about 70% greater unfired strengths compared to ceramic shells made with prior art small particle size silica sols. Prime coats and refractory back-up coats which use the large particle size sol dry about 30% to about 40% faster than prime coats and back up coats which employ the smaller particle size silica sols of the prior art.

Abstract: An article, such as a gas turbine engine mixer, is made by providing a mold structure defining a thin-walled, hollow article, and a base metal that is subject to hot tear cracking when cast in a generally equiaxed polycrystalline form, such as Rene' 108 and Mar-M247. The article is fabricated by introducing the molten base metal into the mold structure, and directionally solidifying the base metal in the mold structure to form a directionally oriented structure. The directionally oriented structure may be formed of a single grain or oriented multiple grains.

Abstract: A method for fabricating a fired ceramic article, a green product, and a fired ceramic article, all for use as a core in the investment casting of directionally solidified eutectic and superalloy material. A ceramic slurry is prepared of alumina, aluminum and a solution of a polymerizable binder in a liquid. The slurry is extruded under low pressure into a closed cavity to form a gelled green product which is subsequently heated in an oxygen-containing atmosphere, wherein the oxygen reacts with the aluminum in the green product to form alumina which advantageously causes an increase in volume of the green product which counters the shrinkage effects of heating.

Abstract: Investment casting shells, methods for their manufacture and methods for casting metals and alloys using such shells are disclosed. One feature of the shells is that the facecoat plus interior backup layers are purposefully designed to have substantially similar coefficients of thermal expansion to the seal dip layers. This helps reduce the occurrence of dimensional casting defects caused by differential thermal expansions of the layers comprising the shell. One embodiment of such a shell comprises a facecoat, plural interior backup layers and plural intermediate backup layers wherein at least one of the plural intermediate backup layers comprises a material capable of undergoing a volumetric transformation during cool down, and wherein the seal-dip layers have a coefficient of thermal expansion that varies from the coefficient of thermal expansion of the facecoat and interior backup layers by less than about 10 percent.

Abstract: A process for rapidly forming a ceramic shell mold on an expendable pattern is disclosed. The process entails use of refractory slurries which include a large particle size colloidal silica sol binder. The colloidal silica sol binder has an average particle size of about 40 nanometers, i.e., about 3-4 times larger than colloidal silica sol binders heretofore employed in manufacture of ceramic shell molds. The use of the large particle sols yields unfired ceramic shell molds which have about 40% to about 70% greater unfired strengths compared to ceramic shells made with prior art small particle size silica sols. Prime coats and refractory back-up coats which use the large particle size sol dry about 30% to about 40% faster than prime coats and back up coats which employ the smaller particle size silica sols of the prior art.

Abstract: Mold coatings that are relatively unreactive with titanium and titanium alloys during casting are prepared from yttria slurries, which may contain other refractory materials, an acid and an inert organic solvent.

Abstract: Mold heating vacuum casting furnace system comprising a mold preheating chamber located above and connected to a vacuum casting chamber via an intermediate isolation valve. A mold elevator is provided in the casting chamber and can be moved into the mold preheating chamber to lower the mold onto an annular rotary chill member residing in the casting chamber. The elevator includes an upstanding elevator shaft that moves in the opening of the annular chill member in a manner that the preheated mold is deposited or set on the annular chill member as the elevator is lowered into the casting chamber. The chill member includes an upwardly diverging mold engaging surface onto which the preheated mold is set by the elevator as it is lowered.

Abstract: A paper receptacle is disclosed designed to improve the investment casting process in vacuum machines. The paper acts as both a vacuum liner and splash guard. It is fabricated as a perforated paper sheet having hooks, which is inserted in a cylindrical manner into casting flasks in order to provide a liner for congealing islands of solid investment plaster onto the surface of the casting flask resulting from the plaster slurry entering the holes; and a splash guard for investment slurry. After burnout, the liner facilitates the production of high-density metal porosity free castings at lower temperatures and in less time and with easy break away of investment plaster from the flask. The splash guard feature eliminates congealed slurry cleanup and prevents vacuum slurry boilover. The space saving resulting from this prevention enables more wax modules to be inserted into flasks increasing production.

Abstract: A solid high silicon cast iron elongated anode has a midpoint electrical connection keeping the connection as far as possible from the ends to combat the deleterious pencil effect. The anode is made by casting using a hollow or shell core to form a small axial hole extending from one end. The sand or foundry material of the core is removed and the wall of the hole at the blind end of the hole is at least partially finished to receive a diagonally split slug to which a lead wire is connected. Alternatively the hole is formed by a steel pipe which is left in place as a hole liner. The pipe may be supported by one or more chaplets. The slug is fastened in the blind end of the hole by a driving tool rotating a threaded headed bolt with both axial and rotational force to hold the connection in the blind end of the hole as it is secured in place. The hole is filled with a potting compound sealing the connection in the center of the solid cast iron anode.

Abstract: The apparatus includes a rubber base with two inlets, a two-chamber ceramic crucible with two identical outlets, and a model of the jewelry item with two sprues connected to two separate tree stems, with each sprue connected to a separate stem thus ensuring flow of different colors or different metals. Simultaneous casting of two different metal alloys of different colors in two separate chambers of the crucible is achieved by using a specially constructed two-head torch.

Abstract: A shell mold includes a plurality of sleeve forming portions. Of the sleeve forming portions, at least an endmost sleeve forming portion located adjacent to a subrunner portion has a modified shape for compensating for deformation of cast sleeves caused by solidification and contraction of molten metal. A shell molding apparatus includes an upper die and a lower die which constitute a die set for molding a shell mold. The lower die is composed of shell molding inserts, each having the shape of a halved cylinder, spiny insert receiving recesses formed in the shell molding inserts, and spiny inserts retractably provided in the spiny insert receiving recesses. In a casting method using a shell mold, many protrusions of a spiny insert are reversely copied to the inner surface of a halved shell mold at the undercut portion of the inner surface, thereby forming many depressions at the undercut portion. The halved shell mold is parted from the lower die.

Abstract: A apparatus casting a turbine wheel of a metal alloy, wherein there is generated a columnar grain structure parallel to the leading and trailing edges of the vanes, by directional solidification of the metal from the central aperture in the wheel outward to the vane tips. A form with cavity to receive therein the molten metal has a thin walled core in the center, with the core wall outer surface in place to provide one wall of the cavity. A heat transfer medium in fluid form is circulated through the core, thereby cooling the poured metal by heat transfer from the inner ends of the vanes outward to the tips.

Abstract: The present invention relates to a method and apparatus for producing a cast structure. In one embodiment of the present invention an alloy casting mold has molten alloy injected therein to facilitate completely filling a part cavity within the mold. Further, an alloy charge pressure control device is utilized to reduce the charge pressure of the molten alloy during its injection into the mold cavity to minimize distortion and creep of the ceramic shell. In one form of the present invention the charge pressure control device removes excess alloy so as to reduce the head pressure of the molten alloy thereby eliminating the undesirable creep of the ceramic shell.

Abstract: Mold coatings that are relatively unreactive with titanium and titanium alloys during casting are prepared from yttria slurries, which may contain other refractory materials, an acid and an inert organic solvent.

Abstract: An apparatus and method for use in casting a metal article includes a mold structure having wall sections with pins extending between the wall sections. The pins have opposite end portions which are embedded in the wall sections of the mold structure to interlock the pins and the wall sections of the mold structure. When molten metal is poured into the mold structure, the molten metal urges the wall sections away from each other. The wall sections are retained against movement relative to each other by the pins. Although the apparatus and method of the present invention can be utilized to cast many different types of articles, the invention is advantageously utilized in the casting of thin metal articles and specifically a thin metal article which is formed as a single crystal.

Abstract: The method for the fabrication of a crystalline blade comprised of two shoulders enclosing an airfoil form which comprises arranging the shells of a mold in a manner such that the shoulders are parallel to the plane of a grain selection baffle that empties into a junction that moves the grain to the two shoulders, and feeding the mold through gates at the upper ends of the shoulders.

Abstract: Method and apparatus for directional solidification (e.g columnar grain or single crystal casting) of a melt involves refractory particulates, such as SiC particles, provided about at least one article molding cavity region of a casting mold wherein the particulates are heated to an elevated temperature above a melt casting temperature. The article molding cavity region of the casting mold is heated from an initial preheat temperature to an elevated casting temperature by heat from the particulates prior to communication of the article molding cavity to a chill member. For single crystal casting, a radiation transparent crystal selector member is disposed in a mold grain nucleation and growth cavity located between the article molding cavity and the chill member to select a single crystal for propagation in the article molding cavity region. A melt permeable, thermal insulation member may be disposed between the mold grain nucleation and growth cavity region and the chill member.

Abstract: In an investment casting process including the known steps of injecting a molten wax into a die, allowing the wax to solidify, removing the die, investing the wax with ceramic, firing the ceramic and removing the wax so as to provide a ceramic mould, and casting a molten material into the mould, and apparatus including a ceramic core the shape and size of the cavity to be provided in the blade, a removable wax impression die surrounding and spaced from the core member so that the space between the die and the core member is the shape and size of the blade, there is provided a number of platinum chaplets adapted and arranged to support and locate the core in relation to the ceramic mould by point contact abutment with an adjacent mould surface.

Abstract: An improved mold for use in casting a metal airfoil has an airfoil mold cavity and a starter chamber. A lower end of the starter chamber is formed by a chill plate. A filter is disposed in the starter chamber between the airfoil mold cavity and the chill plate. When an airfoil is to be cast, molten metal is conducted into the starter chamber, into passages in the filter and into the airfoil mold cavity. The molten metal is solidified upward in the starter chamber from the chill plate and through the passages in the filter. The filter blocks migration of impurities from the starter chamber to the airfoil mold cavity as the metal solidifies in the starter chamber. As the molten metal begins to solidify in the airfoil mold cavity, the molten metal is solidified as a large number of columnar grain crystals which extend from the passages in the filter into the airfoil mold cavity.

Abstract: A casting unit for the manufacturing of a plurality of cast parts by using directed solidification or monocrystal formation as well as the process for casting is provided. A plurality of individual molds are combined while forming close distances to form a mold shell in the manner of an array. In this manner, the simultaneous casting of a large number of cast parts is permitted while the space requirement is minimized.

Abstract: An improved high impact metal clubhead with a unique reinforced composite face wall, increased radius of gyration, and a positive lift air foil surface contour. The composite face wall includes an impact supporting wall rigidified by a pattern of integrally cast reinforcing bars that extend forwardly, rather than rearwardly, from the supporting wall. The reinforced supporting wall is covered by a very hard plastic ball striking insert that is cast in situ over the supporting wall. The increase in radius of gyration is accomplished by extending the heel and toe portions of the clubhead along the face wall further from the geometric center of the head, beyond present day parameters for high impact clubheads. And the positive lift is effected by contouring the top wall of the clubhead downwardly and rearwardly from the base wall more severely almost to the plane of the sole plate, and flattening the rear wall so it is almost co-planar with the sole plate.

Abstract: A high melting point and/or low ductility metal or alloy is investment cast in a refractory mold including a facecoat layer and a plurality of back-up layers wherein at least one back-up layer is a relatively weak, sacrificial layer. This latter layer is crushed as necessary as the casting cools below its ductile-to-brittle transition temperature to avoid hot tearing or cracking of the solidified metal or alloy during cooling in the mold.

Abstract: A method of making a casting having an internal passage involves the steps of forming a core having an external surface configured to form the passage in the casting and having a plurality of integrally formed protrusions extending from the external surface at stressed regions thereof (e.g., thermally stressed regions) prone to be distorted from a master core configuration, and positioning the core in a pattern molding cavity by engagement of the protrusions with rigid walls defining the molding cavity such that the core is conformed substantially to a predetermined and/or empirically determined relationship between the master core configuration and the molding cavity as if the core corresponded to the master core configuration. A fugitive pattern corresponding to the casting to be formed is then molded about the external surface of the core while the core is supported in the aforementioned relationship relative to the molding cavity, whereby the wall thickness of the pattern is controlled about the core.

Abstract: A process for the production of castings by directional or monocrystalline solidification is carried out in a vacuum casting plant which, apart from a conventional cooling plate, has no additional heating devices for the casting mold. The unidirectional heat flow required to guide the solidification front is produced on the one hand, by heat sources formed partially from superheated melt and, on the other hand, by heat sinks consisting of the cooling plate and the surroundings of the mold. The mold is heated in a separate heating-up oven to a temperature above the liquidus temperature of the melt in order that the casting mold may contribute to the heat source in addition to the melt so doing.

Abstract: Casting cores particularly useful in the investment casting industry are described. The cores are characterized by the presence of hollow ceramic particles, which facilitate the removal of the core from the casting they are used to form. In a preferred embodiment of the invention, the core is characterized by solid and hollow ceramic particles sintered to each other to form a core matrix, and such particles have the same composition. In an even further preferred embodiment, high temperature stable fibers are distributed uniformly throughout the matrix.

Abstract: Apparatus and method for countergravity casting a melt employs a particulate mass disposed in a container about a mold having a mold cavity, an ingate passage communicated to the mold cavity for supplying the melt to the mold cavity, and a separate, preformed riser-forming member connected to the mold so as to communicate to an isolated and/or enlarged region of the mold cavity needing additional melt supply during solidification in the mold. The mold ingate passage and a source of the melt are communicated to conduct the melt through the ingate passage to the mold cavity to fill the mold cavity with the melt and form a riser of melt in the particulate mass. The riser of melt provides a source of additional melt for supply, as necessary, to the isolated and/or enlarged region during solidification of the melt in the mold cavity to accommodate melt shrinkage thereat.

Abstract: A casting mold is disclosed for preventing growth of parasitic grains in the casting of a workpiece from a liquid metal by a single crystal solidification technique. The mold has a mold portion which defines a casting cavity in the shape of the desired workpiece as well as a feeder portion which defines a separate feeder cavity not in communication with the casting cavity. The feeder portion is in heat exchange contact with the mold and is located adjacent to the areas of the workpiece in which a parasitic grain may be nucleated during the controlled solidification. The feeder portion is filled with a thermal mass which emits heat to slow the liquid metal solidification in these zones in order to prevent a growth of the parasitic grain. The thermal mass in the feeder cavity may consist of a liquid metal which undergoes a phase change at the same temperature, or a slightly higher temperature than that of the liquid metal located in the casting cavity from which the workpiece is cast.

Abstract: A reinforced ceramic investment casting shell mold and method of making such mold. The ceramic investment casting shell mold includes alternate, repeating layers of a ceramic material and a ceramic stucco defining an overall thickness of the shell mold. A fibrous reinforcing material is disposed in the alternate, repeating layers at an intermediate thickness of the shell mold. The fibrous reinforcing material has high tensile strength at elevated temperature and a coefficient of thermal expansion that is less than the coefficient of thermal expansion of the ceramic material and the ceramic stucco. The fibrous reinforcing material is preferably woven into a twisted yarn and disposed in a generally spiral configuration.

Abstract: An improved high impact metal clubhead with a unique reinforced composite face wall, increased radius of gyration, and a positive lift air foil surface contour. The composite face wall includes an impact supporting wall rigidified by a pattern of integrally cast reinforcing bars that extend forwardly, rather than rearwardly, from the supporting wall. The reinforced supporting wall is covered by a very hard plastic ball striking insert that is cast in situ over the supporting wall. The increase in radius of gyration is accomplished by extending the heel and toe portions of the clubhead along the face wall further from the geometric center of the head, beyond present day parameters for high impact clubheads. And the positive lift is effected by contouring the top wall of the clubhead downwardly and rearwardly from the base wall more severely almost to the plane of the sole plate, and flattening the rear wall so it is almost co-planar with the sole plate.