Abstract: A ceramic-metal composite that is tough and stiff has been prepared and is comprised of an inert ceramic (e.g., alumina) embedded and dispersed in a matrix comprised of a metal (e.g., aluminum), a reactive ceramic (e.g., boron carbide) and a reactive ceramic-metal reaction product (e.g., AlB2, Al4BC, Al3B48C2, AlB12, Al4C3, AlB24C4 or mixtures thereof) wherein grains of the inert ceramic have an average grain size greater than or equal to the average grain size of grains of the reactive ceramic. The ceramic-metal composite may be prepared by forming a mixture comprised of an inert ceramic powder (e.g., alumina) and a reactive ceramic powder (e.g., boron carbide), the inert ceramic powder having an average particle size equal to or greater than the average particle size of the reactive ceramic powder, forming the mixture into a porous body and consolidating the porous body in the presence of a metal (e.g., aluminum) to form the ceramic-metal composite.

Abstract: A preform for use in a metal matrix composite, particularly for a magnesium metal composite, and a metal matrix composite, typically made by squeeze casting, using the preform. In the preform the reinforcing material typically is silicon carbide, boron nitride, carbon or graphite. The binder used in the preform is magnesium fluoride, which avoids the known problems which result from the high reactivity of magnesium metal with other binders, such as silica and alumina, which results in the formation of magnesium oxide in the reinforced composite. The presence of magnesium oxide crystals in the metal matrix adversely affects the properties of the composite.

Abstract: A vehicle wheel mold is vibrated during a casting process. The vibration reduces the solidification time needed to form a wheel casting while improving tensile strength of the wheel.

Abstract: A method of making a spray formed rapid tool includes the steps of making a model of a desired tool and directly constructing a sand pattern as the inverse of the model. The method also includes the steps of thermally spraying metal material against the sand pattern to form the desired tool.

Abstract: An intermediate material is formed by coating at least a half of the surface of a function selecting material having at least one of physical property values that are different from those of a casting metal material forming a cast product with a coating metal material and the casting metal material is cast together with the intermediate material to form a composite body in casting the product.

Abstract: A method for forming a heat transfer apparatus wherein a conduit construct is formed between first and second construct ends and is disposed in a mold cavity with the first and second ends extending from the cavity, air is removed from the construct, body material in molten fluid form is provided in the cavity so as to cover the construct and the molten material is permitted to solidify. In addition, the invention includes a manganese/nickel barrier material which is placed on a conduit construct prior to introducing molten material into the cavity to reduce bubbles in the sink. The invention also includes a system for maintaining heat sink temperature despite fluctuating amount of heat generated by devices mounted to or adjacent a sink wherein the system includes a temperature sensor, a controller and a regulator, the controller controlling the regulator as a function of feedback signals received from the sensor.

Abstract: A composite material having less than about 25 volume percent refractory particles in a metal matrix is concentrated to have about 37-45 volume percent refractory particles. The concentrating is accomplished by heating the composite material to melt the matrix, and then contacting the molten composite material to a porous element having an average pore size greater than that of the average particle size. A small pressure differential, on the order of about one atmosphere, is applied across the porous element, so that metal matrix material separates from the composite material and flows through the porous element. The particulate volume fraction in the composite material gradually increases. When the particulate volume fraction exceeds about 37 volume percent, the mass of composite material becomes semi-solid and freestanding. The resulting composite material may be further processed, as by forming to a useful shape or diluting with another matrix material.

Abstract: A multi-piece crankshaft having a main shaft with two ends adapted to rotate about its axis. A crankpin also has two ends and an axis parallel to but radially spaced from the axis of the main shaft. At least one counterweight extends between one end of the shaft and one end of the crankpin and this counterweight is formed by casting a liquid metal around the ends of the main shaft and crankpin in a molding chamber. In a modification of the invention, a hollow crankpin is disposed within the mold such that each end of the crankpin is positioned within a mold cavity corresponding to a counterweight. Upon casting the liquid metal in the mold cavities forming the counterweights, the molten metal flows inwardly from both ends of the crankpin and joins together to form a continuous metal connection between the counterweights.

Abstract: A mold is provided which is capable of producing a sound fiber-reinforced composite article utilizing a die-casting process. A cavity in the mold includes a composite article forming area in which a formed product of fiber is located, a molten metal storing area located adjacent the composite article forming area to fill a molten metal into the formed product of fiber, and a molten metal flow slackening area for reducing the turbulent flow of the molten metal from gates to introduce it to the molten metal storing area. Thus, the flow of the molten metal introduced into the molten metal storing area, is brought into a substantially laminar flow state, so that the inclusion of air in the molten metal flow is inhibited. Therefore, the molten metal in the molten metal storing area can be smoothly filled into the formed product of fiber under pressure.

Abstract: A process for preparing a preform for use in a metal matrix composite, particularly for a magnesium metal composite, and a metal matrix composite, typically made by squeeze casting, using the preform. In the preform the reinforcing material typically is silicon carbide, boron nitride, carbon or graphite. The binder used in the preform is magnesium fluoride, which avoids the known problems which result from the high reactivity of magnesium metal with other binders, such as silica and alumina, which results in the formation of magnesium oxide in the reinforced composite. The presence of magnesium oxide crystals in the metal matrix adversely affects the properties of the composite.

Abstract: An electronic apparatus such as a portable computer comprises an electronic apparatus frame and a raised portion provided on that region of the electronic apparatus frame which engages an ejector pin projecting from inside a mold device and formed thicker than the other part of the electronic apparatus frame.

Abstract: The present invention relates to a novel method for forming cast metal matrix composite bodies. In particular, the present invention relates to a novel method for forming or recycling metal matrix composite bodies so as to render such bodies in a condition for casting or recasting as a cast metal matrix composite body. Specifically, a scrap metal matrix composite body and preferably a scrap cast metal matrix composite body is placed into a crucible, optionally along with unreinforced matrix metal and/or virgin metal matrix composite material. Whether the scrap and/or virgin materials are placed into the crucible in solid or molten form, the contents of the crucible are ultimately rendered molten to form a composite melt.

Abstract: A method of connecting elements in a vehicle frame includes fixing the elements in a desired orientation, positioning dies to surround a portion of each element, and introducing material into the die cavity thereby casting a node around the elements.

Abstract: The invention concerns a process for manufacturing a part made of high temperature-resistant, ceramic material based on aluminum nitride and reaction sintering. The process comprises the steps of preparing a homogeneous mixture of boron nitride powder, aluminum powder and a paste-like binder, capable of solidifying by chemical reaction and by solvent loss through drying. The mixture is formed by mold casting and then pressed and heated, to a temperature not exceeding approximately 70° C., to harden the binder and to obtain a solid and manipulable unfired part. The binder is eliminated by heating to a temperature of approximately 300° C. Pores of the unfired part are impregnated by immersing the part in a bath of molten aluminum or aluminum alloy to form an impregnated preform. Thereafter, the impregnated preform is removed from the bath, cooled, and machined to the final dimensions of the part. A ceramic is obtained by reaction sintering the machined part at a temperature of 900 to 1000° C.

Abstract: A crank arm for a bicycle includes a crank arm body having a pedal attachment hole on a first end thereof and a spindle attachment hole on a second end thereof. The crank arm body defines an elongated interior cavity surrounded by a shell, wherein the interior cavity is open to an exterior of the crank arm body. The opening can be used to access the cavity during and after manufacturing. The shape of the cavity may be varied to produce a lightweight yet strong structure. In the method used to form the crank arm body, a mold core formed by a shell containing a sand-like filler material is positioned into a casting mold so that a melt space is formed around the mold core, molten metal is poured into the casting mold, and the molten metal is solidified to form a crank billet. The filler material may be removed through an opening in the crank billet.

Abstract: A method for producing a golf club head includes: preparing a plurality of face plates that complement with one another to form the golf club head; joining edges of the face plates to form a shape of the golf club head, and providing grooves which extend between the adjoining edges of the face plates and which open at an outer surface of the golf club head; and welding the adjoining edges by placing the joined face plates in a mold and by introducing a solder into the mold casting in the grooves.

Abstract: A light-weight metal matrix composite includes a bimodal distribution of ceramic particles which are uniformly distributed within a metal or alloy matrix. The bimodal distribution includes a first component of ceramic particles having an average particle size of less than 1 micron and a second component of ceramic particles having an average particle size of about 5 to 15 microns. The metal matrix composite includes from about 15 to 30% by weight of the first component and from about 2.5 to about 10% by weight of the second component. At least 80% of the particles in the first component are uniformly distributed so that the particle spacing does not exceed 3 times the diameter of the largest cross sectional dimension of the particles in the first component and at least 80% of the ceramic particles in the second component are uniformly distributed so that the inner particle spacing does not exceed 3 times the diameter of the largest cross sectional dimension of the particles in the second component.

Abstract: A mold cavity in a mold vessel is evacuated. A charge of molten infiltrant is transported into the mold vessel while the vacuum is maintained in the mold cavity. Pressure is applied to the molten infiltrant to move the molten infiltrant from the mold vessel into the mold cavity. The molten infiltrant is cooled in the mold cavity to solidify the infiltrant. A fill tube can be used to transport the infiltrant to the mold vessel.

Abstract: A connecting board is provided for disposition between a base plate such a LGA base plate and a mounting board such as a printed circuit board. The connecting board has a substrate having a plurality of through holes. Each through hole extends between opposite first and second surfaces of the substrate. An easily deformable soft metal body is mounted in each through hole in such a way as to have protruded portions protruding from the first and second surfaces of the substrate. The protruded portions of the soft metal body are different in protruding height. The connecting board are connected at the protruded portions to the base plate and the mounting board. The heights of the protruded portions are set depending upon the materials and the coefficients of thermal expansion of the LGA base plate, printed circuit board and connecting board.

Abstract: A thruster rocket engine throat insert (12) has a thin walled shell (54) made from a high strength, oxidation resistant material. The shell (54) having a throat (48) of reduced cross-section and a radially extending annular stiffening ring (60) located at the throat (48). A casing (56) made from a material having a thermal conductivity at least 10 times greater than that of shell (54) is molded around an outer surface (58) of shell (54) and has a generally cylindrical exterior surface (59). Shell (54) resists yielding and oxidation caused by the extreme temperatures of rocket fuel combustion products passing through the throat insert (12), while the casing (56) acts to efficiently transfer heat from the shell (54).

Abstract: A torque support mountable between a first housing of a driven unit and a second housing of a driving unit includes a scalloped one-piece plastic base body having a first side connectable with the first housing and a second side connectable with the second housing so as to be fixed with respect to rotation relative to both the first housing an the second housing. The first side includes a first planar contact face with through-openings for fastening with the first housing and the second side includes a flange-like edge area with a second planar contact face for resting against the second housing. The plastic piece is injection molded with support webs and includes metal bushings which are arranged perpendicular to the second planar contact face to provide a torque support which is simple and economical to manufacture, mechanically stable, has a certain elasticity and is adaptable to virtually any gear unit connection surfaces.

Abstract: A disk drive including voice coil magnet plates formed integrally with the base and/or cover of the disk drive. During the fabrication process, the steel magnet plates are placed in proper position in the base and cover die casting, and then the molten aluminum is injected to form the base and cover. As result, the magnet plates are integral with the base and cover and no fluid leakage can occur around the boundary between the top magnet and cover, or around the boundary between the bottom magnet and base. Thus, the disk drive is sealed against the external environment.

Abstract: Alumina tiles within aluminum framing jigs are fixedly positioned by lock ns within an internally coated mold for centrifugal casting within a block of an aluminum alloy material. Such jigs and the tiles framed therein are coated with silver before casting to prevent aluminum oxidation by heating of the aluminum material to a molten state for deposit into the mold. Bonding of the tiles and framing of the jigs with the aluminum material being cast is also enhanced by such silver coating.

Abstract: The article is produced by prepositioning nonwoven reinforcement, coated h a bond enhancing compound inside of a centrifugal casting mold that is surface coated for protective shielding of the reinforcement. Molten matrix metal is then introduced into the mold while being rotated about its longitudinal axis until the molten metal completely encapsulates the reinforcement.

Abstract: A method of making a coupling assembly for use in a loading adapter of a gasoline tanker trailer. The coupling includes an aluminum coupling body and a wear resistant bronze sleeve. The wear resistant bronze sleeve provides a durable surface for receiving latches. The sleeve does not bond to the coupling body, but rather is constrained thereto by physical interference.

Abstract: Long life wear parts are cast with mounting structures at proximal ends and relatively thin carbide layers at distal ends. The distal end carbide layers are filled with cast carbide material and distal faces of the cast steel wear parts are covered with the thin carbide layer. Hardness of the wear parts increases toward the distal end. The proximal end is left unhardened to provide strength and resist breaking, and resist wearing of the base and fasteners which mount the wear parts. In one form portions of distal ends of molds are lined with sintered tungsten-carbide steel wear surfaces before parts are cast.

Abstract: A cast composite sector gear including a hub made of a first material and an outer gear section made of a second material that is cast onto the hub. The hub is configured such that a secure mechanical bond can be created between the hub and the gear section when the gear section is cast onto the hub. The hub includes a base having a peripheral surface and a gear foundation that extends circumferentially from the peripheral surface about a portion of the base. The gear section is cast onto the gear foundation, and the gear section extends circumferentially about a portion of the hub.

Abstract: A method for preparing a light metal or light metal alloy composite product, wherein (a) an aqueous slurry containing water, a reinforcement powder, a metal powder and an alumina sol binder is prepared; (b) a preform is prepared from the slurry; (c) the preform is sintered; and (d) the sintered preform is impregnated with a melt of a light metal or a light metal alloy to produce a light metal or a light metal alloy based composite product.

Abstract: A porous composite forming material is held in a cavity of a casting mold, and molten light alloy is poured into the cavity of the casting mold through a gate. Then a gas pressure is applied to the cavity in the casting mold with the cavity closed, thereby impregnating the pores of the porous composite forming material with the molten light alloy and forming a composite portion formed of a composite material of the light alloy and the composite forming material.

Abstract: A process of making a vane for a rotary expansible chamber device, comprising the steps of: providing an open vane die having a die cavity, wherein said die cavity comprises a body cavity section corresponding to a body of the vane, a first tip cavity section corresponding to a first tip of the vane, and a second tip cavity section corresponding to a second tip of the vane; providing a preheated, porous carbon preform in the first tip cavity section of the vane die, the preform having a shape corresponding to at least a portion of the first tip cavity section; closing the vane die; injecting a castable admixture comprising a metal alloy and a plurality of inorganic particles into the die cavity and filling the vane die cavity with the injected admixture; impregnating the preform with the metal alloy of the injected admixture, substantially all of the inorganic particles from the injected admixture being filtered out by the preform as the admixture flows into the preform; allowing the castable admixture to sol

Abstract: A composite metallic cast article (A) includes a shell (28) having a predetermined solid phase density. A non removable insert (24) is at least partially embedded within the shell (28). The insert (24) is fabricated from a foamed metal substance having a substantially lower solid phase density than the shell (28). The foamed metal insert (24) may have a layer of skin (26) fused with the molten metal of the shell (28) during the casting process. Tapered locating pins (30) or other spacing elements position the insert (24) within the mold cavity (18) to prevent shift during the casting operation. The foamed metal insert (24) reduces the time and expense involved in removing a traditional casting core after the casting operation is complete. Also, the insert (24) can be completely enclosed within the shell (28) of the article (A), thereby expanding the design capabilities of such cast articles (A).

Abstract: A method of die casting a cylinder block of aluminum wherein cylinder liners of another material are cast in. A cylinder insert component (14) is placed in the liner, leaving a gap (a) between the outer surface of the insert component and the inner surface of the liner. Pressurized aluminum melt flows against the outside of the liner and is allowed to flow into the gap via a passage (22) between the lower edge of the liner and a lower insert component (15), so that there will be the same pressure on the outside and inside of the liner. The aluminum inside the liner is then machined away.

Abstract: Thin automobile components, such as a transmission case made of an aluminum alloy, are provided which are less likely to create vibration-derived noise. An aluminum alloy member, with an insert provided therein, possessing improved damping capacity, comprising: an austempered graphite cast iron member inserted into an aluminum alloy with the thickness of a section constituting a product being not more than 6 mm. A process for producing an aluminum alloy member, with an insert provided therein, wherein cooling is performed so as for the temperature of a graphite cast iron material to reach 400.degree. C. or below within 10 sec after pouring of an aluminum alloy. The graphite cast iron material comprises by weight 2.5 to 4.0% of carbon, 2.0 to 3.5% of silicon, 0.1 to 0.8% of manganese, and at least one member selected from the group consisting of 0.1 to 2.0% of copper, 0.1 to 2.0% of nickel, and 0.05 to 0.5% of molybdenum with the balance consisting of iron and unavoidable impurities.

Abstract: A method of integrating detailed features into a spray formed rapid tool includes the steps of making a model of a desired tool and constructing a ceramic pattern as the inverse of the model. The method also includes the steps of locating at least one detailed feature insert on the ceramic pattern and thermally spraying metal material against the detailed feature insert and ceramic pattern to form the desired tool and embedding the detailed feature insert into the desired tool.

Abstract: A heat-resistant, thermally insulative, ductile port liner for a head of an internal combustion (IC) engine having a tube-shaped structure formed from at least one layer of fiber reinforced ceramic matrix composite (FRCMC) material. The FRCMC material includes a polymer-derived ceramic resin in its ceramic form and fibers. In a first embodiment of the port liner, the tube-shaped structure has one FRCMC layer forming the sole, solid wall of the structure. Whereas, in a second embodiment, the tube-shaped structure has two FRCMC layers forming inner and outer walls of the structure, respectively, with an intervening space separating the inner and outer walls. The intervening space is sealed at both ends. It can be filled with a thermally insulating material, evacuated and held at substantially a vacuum pressure, or filled with a gas. Once the port liner has been formed, it is preferably cast-in-place when the metal head of the IC engine is formed.

Abstract: In a method of integrally attaching a hollow member to a cast product by casting so that the hollow member communicates with a hollow interior of the cast product, a closure member is fitted into an open end of the hollow member so that the open end of the hollow member is closed by the closure member. The closure member projects from a core for forming the hollow interior of the cast product in a direction different from a direction in which the core is drawn out of the cast product. A molten metal is poured into a casting mold after the casting mold has been clamped. The closure member is moved inside the core after solidification of the molten metal so that the closure member is released from the fitting in the hollow member. The core is drawn out of the solidified metal subsequently to the moving step of the closure member.

Abstract: A method of forming a breakage resistant, erosion resistant ceramic liner for a part comprising the steps of, forming a liner of a ceramic material containing pores; filling the pores with a pre-ceramic polymer resin; and, firing the liner saturated with a pre-ceramic polymer resin at a temperature and for a time which converts the resin into a ceramic within the pores. The liner can be mechanically attached, adhesively bonded or, a metal part can be cast onto the liner by placing the liner within the metal casting mold for the part as a sidewall or integral element thereof. The invention also includes method for producing parts and liners of fiber reinforced ceramic matrix composite by a resin transfer molding process or the like wherein fiber preforms are saturated with liquid pre-ceramic polymer resin. The preforms are then polymerized in a mold, the part removed from the mold, and then fired to transform the polymer to ceramic. The process can also be employed to form hollow parts such as manifolds.

Abstract: A formed porous body of oxide ceramic and an aluminum alloy block are placed in a crucible in an atmospheric furnace, and a magnesium source is placed in another crucible in the atmospheric furnace. An argon gas is then introduced into the atmospheric furnace, which is then heated to produce a magnesium vapor from the magnesium source and melt the aluminum alloy block. Then, the argon gas is replaced with a nitrogen gas to generate magnesium nitride. The magnesium nitride reduces an oxide on surfaces of the formed porous body, exposing metal atoms on the surfaces of the formed porous body. The molten aluminum alloy permeates the formed porous body under a pressure lower or higher than the atmospheric pressure or alternate pressures lower and higher than the atmospheric pressure.

Abstract: A method for forming integral extensions on the end of directionally oriented, superalloy articles, such as airfoil blading members or other components used in gas turbine or other turbine engines. An extension is formed directly on an article by dipping a portion or end of the article into a molten bath of a compatible alloy, followed by withdrawal of the end under controlled conditions sufficient to cause an integral extension to solidify on the article. A ceramic mold is utilized over the dipped end of the article with a mold cavity that generally defines the shape of the extension to be formed. The mold may be formed in situ, or preformed and attached to the subject article. Extensions formed by the method of this invention have a microstructure that is continuous and compatible with that of the article. Such microstructures may include epitaxial growth of the extension from the microstructure of the article.

Abstract: A process for preparing complex-shaped, ceramic-metal composite articles, comprising:a) contacting a non-wettable powder that is non-wetting to a metal to be used for infiltration with a shaped ceramic body to form a layer(s) of the non-wettable powder on one or more surface(s) of the shaped ceramic body wherein the shaped ceramic body has a region(s) where there is no layer of the non-wettable powder;b) infiltrating the shaped ceramic body with the metal through the region(s) where there is no layer of the non-wettable powder such that a complex-shaped ceramic-metal composite comprising one or more metal phases and one or more ceramic phases is formed, wherein the article has substantially the net shape of the shaped ceramic body and the undesirable regions of excess metal on the surface and undesirable phases within the complex-shaped ceramic-metal composite article near the surface are located only in the region(s) where there is no layer of the non-wettable powder.

Abstract: Metal matrix composites are made by infiltrating packed loose fly ash with molten metal or metal alloy under low pressure. In some embodiments the infiltration is driven by pressurized gas. Coating the fly ash prior to infiltration can lower the threshold of pressure required for satisfactory infiltration by the molten metal. In some embodiments nickel coated cenosphere fly ash is employed. Resulting metal-fly ash composites have high volume fractions of fly ash, and the fly ash is uniformely distributed in the metal matrix. The densities of the composites are relatively low, particularly in composites made using cenosphere fly ash.

Abstract: A metal ground engaging tool (GET) component is selected. One or more critical wear surfaces on the GET component are identified. The GET component is selectively reinforced by depositing one or more metal matrix composite components at the one or more identified critical wear surfaces on the GET component. The metal matrix composite components consist of a reinforcement preform and a metal. The preform is formed from a material selected from one of ceramic, cermet, or mixtures thereof. The metal is selected from one of iron, alloy steel, or mixtures thereof. The reinforcement preform is present in the metal matrix composite in the range of about 30% to about 60% by volume.

Abstract: Method of making MMC components by an infiltration process, with a preform (3) which is disposed inside a crucible (6) and, optionally, held by a preform holder (2), being placed inside a pressure container (1), wherein the atmosphere inside the pressure container (1) is changeable during the production process, and after the infiltration metal (4) has melted on, the preform (3) is contained inside a sealed atmosphere in the presence of an oxygen-binding material.

Abstract: This invention discloses an exhaust manifold for an engine made of all fiber reinforced ceramic matrix composite material so as to be light weight and high temperature resistant.

Abstract: Metallic articles having heat transfer channels are produced by solidification of molten metallic material about pre-formed channel defining members such that a solidified metallic deposit having heat transfer channels is formed. The channel defining members may be in the form of either solid elements (which are subsequently removed to leave the channels), or conduit elements (which may remain permanently embedded in the article). Moulds, dies, cores and other tools for use in moulding or casting of plastics and metals are particularly suitably formed by the process, the heat transfer channels being used for cooling of the respective articles during use. The molten metallic material is preferably deposited by spray forming utilizing one or more sprays of molten metallic material.

Abstract: A process of making a casing having at least one open end and formed with electric conducting passages and connections for electronic components or switching circuits, includes the following steps: preparing a formed body, made of ceramics, glass, glass-ceramics, metal or silicon carbide, with passageways in form of bores and/or indentations, placing the formed body in a mold and pouring liquid metal in the mold to surround the formed body, thereby filling the first passageways, and removing metal from the formed body to leave metal only in the first passageways.

Abstract: A method of manufacturing herringbone gears using an injection molding process is provided. The process involves the use of two separable mold halves each of which include a mold cavity for molding one half of the gear. Moldable material is injected into the mold halves when they are in a sealing abutting engagement. After the material solidifies, the mold halves are separated and the gear is simultaneously unscrewed from each mold cavity.

Abstract: A vehicular brake assembly comprises brake shoes and a brake disc. The brake shoes are fastened to a sheet plate and mounted inside an inner drum portion of the brake disc. The brake disc is operatively connected to an axle placed within a stationary axle housing that carries a mounting flange. The sheet plate is fastened to the mounting flange. An anchor pin is attached to the mounting flange and an opening is made in the sheet plate for the anchor pin to project therethrough to thereby serve as an abutment surface for the brake shoes transferring any force exerted on the brake shoes directly to the mounting flange. The brake disc is operatively engaged with a caliper adapted to grip an outward portion of the brake disc. The caliper slides are provided on the mounting flange to receive the caliper.

Abstract: A composite rotor for caliper disc brakes and the like includes an outer friction portion having two ring sections, with a plurality of supports extending therebetween to fixedly interconnect the ring sections in a mutually parallel, spaced apart relationship defining a cavity therebetween. The ring sections have opposite friction surfaces which interface with associated friction members. The rotor also includes an inner hub portion having a central mounting section which mounts the same on a drive member, and a peripheral section cast into the cavity of the outer friction portion to integrally interconnect the inner hub and outer friction portions of the rotor with primarily mechanical bonds formed at an unfused interface.

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.