A method for manufacturing a golf club head having a weight member includes: providing a weight block made of a metal material; disposing an isolation layer on the weight block to form the weight member; delivering a wax material to form a wax pattern covering a portion of the weight member; coating the weight member and the wax pattern with a shell mold plaster to form a shell mold covering the same; performing a de-waxing process which leaves a mold cavity in the shell mold; and casting a molten metal material in the mold cavity to form a club head main body, and removing the shell mold to form the golf club head having the weight member embedded in the club head main body. A golf club head manufactured by the method is also disclosed.

The present invention relates to a foundry core, which has the base form of a hollow body, with the foundry core being formed from a moulding material consisting of a mixture which is formed from a moulding sand and a binder and optionally from additives added to set its properties and a method for its manufacture. The foundry core according to the invention can be easily manufactured. This is achieved as a result of the foundry core being divided into at least two sub-segments and forming elements interacting with one another in a positive-locking manner being provided on the edge sides, with which sub-segments arranged adjacent to one another abut on one another, or in proximity to these edge sides, via which forming elements the sub-segments arranged adjacent to one another are fixed by positive locking immovably against one another at least in one direction.

A component is formed from a component material introduced into a mold assembly. The mold assembly includes a mold that has a cavity defined therein by an interior wall. The cavity receives the component material in a molten state to form the component. A multiple component core assembly is positioned with respect to the mold and has a first core component attached to a second core component at a core split line. A core connection component is attached to each of the first and second core components at the core split line, such that the first core component is held adjacent the second core component at the core split line. The core connection component is formed from a connection component material that is at least partially absorbable by the component material.

A component is formed from a component material introduced into a mold assembly. The mold assembly includes a mold that has a cavity defined therein by an interior wall. The cavity receives the component material in a molten state to form the component. A multiple component core assembly is positioned with respect to the mold and has a first core component attached to a second core component at a core split line. A core connection component is attached to each of the first and second core components at the core split line, such that the first core component is held adjacent the second core component at the core split line. The core connection component is formed from a connection component material that is at least partially absorbable by the component material.

A method of forming a component by investment casting includes disposing at least a portion of an investment casting pin within a core. The investment casting pin includes a ceramic base pin having a perimeter and a length extending perpendicular to the perimeter and a sacrificial coating disposed about the perimeter of the ceramic base pin along at least a portion of the length of the ceramic base pin. A metal casting is formed around the core. The core and the sacrificial coating are leached with a leaching solution and the investment casting pin is removed from the metal casting.

A method of forming a component by investment casting includes disposing at least a portion of an investment casting pin within a core. The investment casting pin includes a ceramic base pin having a perimeter and a length extending perpendicular to the perimeter and a sacrificial coating disposed about the perimeter of the ceramic base pin along at least a portion of the length of the ceramic base pin. A metal casting is formed around the core. The core and the sacrificial coating are leached with a leaching solution and the investment casting pin is removed from the metal casting.

A method of forming a casting with a flow passage may include filling a tubular pipe with a filler to form a smart core; inserting the smart core into a mold having a cavity corresponding to a shape of the casting to be formed; injecting a molten metal into the cavity through a casting process; and removing the filler from the smart core, wherein a hardness of the tubular pipe is 70 Hv or more.

A method of supporting a soluble insert structure within a mould die ceramic injection moulding (CIM) process, the method comprising the steps of: forming at least one chaplet that supports the soluble insert structure within the die, the chaplet being formed of a ceramic material that has substantially similar physicochemical properties to the main internal core structure; and positioning the chaplet to contact the soluble insert structure to the die, the soluble insert being spaced away from an edge of the mould die. The chaplet may comprise a refractory material or a combination of refractory materials.

A method for manufacturing a metal component using lost-wax casting is provided. The component is made of, for example, nickel alloy, with a columnar or monocrystalline structure with at least one cavity of elongate shape. The method includes creating a wax model of the component with a ceramic core corresponding to the cavity, creating a shell mold around the model, placing the mold in a furnace, with the base standing on the sole of the furnace, pouring molten alloy into the shell mold, solidifying the poured metal by gradual cooling from the sole in a direction of propagation.

A method for manufacturing a metal component using lost-wax casting is provided. The component is made of, for example, nickel alloy, with a columnar or monocrystalline structure with at least one cavity of elongate shape. The method includes creating a wax model of the component with a ceramic core corresponding to the cavity, creating a shell mold around the model, placing the mold in a furnace, with the base standing on the sole of the furnace, pouring molten alloy into the shell mold, solidifying the poured metal by gradual cooling from the sole in a direction of propagation.