Damascus steel hitting surface on golf irons

Abstract

Embodiments relate to a golf club head comprising, a body comprising a shell and a face; the shell comprising a hosel, a first periphery, and a back made of a non-layered material; the face comprising a Damascus Steel comprising a plurality of layers of at least a first material and a second material; the face comprising a second periphery, wherein the second periphery of the face is attached to the first periphery of the shell; wherein a first thickness of a sweet spot of the face is greater than the second thickness of other areas of the face; wherein the face comprises a decorative pattern formed from Damascus Steel; wherein a hardness of the face comprising the Damascus Steel on a Rockwell scale is at least 45 HRC; and wherein the golf club head is an iron type golf club head.

1 - 33 . (canceled) 
     
     
         34 . A golf club head comprising:
 a body comprising a shell and a face;   the shell comprising a hosel, a first periphery, and a back made of a non-layered material;   the face comprising a first layer comprising a Damascus Steel and a second layer comprising a bulk-solidifying amorphous alloy, and wherein the Damascus Steel comprises a plurality of layers of at least a first material and a second material; and wherein the second layer is formed in a geometric shape comprising one of a honeycomb structure, an X shaped band, a plus shaped band, a circular bullseye shape, and a wire mesh;   the face comprising a second periphery, wherein the second periphery of the face is attached to the first periphery of the shell, wherein the first periphery is attached along a boundary connecting a heel edge, a crown edge, a toe edge, and a sole edge of the second periphery; and   a cavity formed behind the face and within the body, the cavity extending rearward from the face to the back of the shell;   wherein a first thickness of a sweet spot of the face is greater than a second thickness of other areas of the face;   wherein the face comprises a decorative pattern formed from the Damascus Steel;   wherein a hardness of the face comprising the Damascus Steel on a Rockwell scale is at least 45 HRC; and   wherein the golf club head is an iron type golf club head.   
     
     
         35 . The golf club head of  claim 34 , wherein the face has a surface area at least 60 square centimeters and the first thickness of the face is in a range of 0.1 centimeters to 0.25 centimeters. 
     
     
         36 . The golf club head of  claim 34 , wherein the second periphery of the face is attached via a welding to the first periphery of the shell using one of a welding, adhesive, and a screw attachment. 
     
     
         37 . The golf club head of  claim 34 , wherein the first material and the second material are selected from a group consisting of titanium, steel, Stainless steel, and composites thereof. 
     
     
         38 . The golf club head of  claim 34 , wherein the first layer is towards the shell and the second layer forms a hitting surface. 
     
     
         39 . The golf club head of  claim 34 , wherein the sweet spot of the face is at least 10% thicker than the other areas of the face, and wherein the first thickness is distributed circularly along the sweet spot of the face. 
     
     
         40 . The golf club head of  claim 34 , wherein the golf club head is part of a golf club. 
     
     
         41 . The golf club head of  claim 34 , wherein the first thickness to the second thickness is at least one of a continuous variation and an abrupt variation. 
     
     
         42 . The golf club head of  claim 34 , wherein the golf club head produces an audio feedback upon impact of a golf ball based on a location where the golf ball is hit on the face. 
     
     
         43 . The golf club head of  claim 34 , wherein the second layer further comprises plurality of layers. 
     
     
         44 . The golf club head of  claim 34 , wherein the sweet spot on the face further comprises colored rings around the decorative pattern formed from the Damascus Steel. 
     
     
         45 . The golf club head of  claim 34 , wherein a backside of the face comprises a ring that marks the sweet spot, wherein the ring comprises at least one of a color and a finish different from rest of the face. 
     
     
         46 . The golf club head of  claim 34 , wherein the Damascus Steel has at least 2 times yield strength of that of a material used for the shell. 
     
     
         47 . The golf club head of  claim 34 , wherein the face is heat treated. 
     
     
         48 . The golf club head of  claim 34 , wherein the decorative pattern is configured to indicate the sweet spot on the face to mark a center of a hitting zone. 
     
     
         49 . The golf club head of  claim 34 , wherein the cavity behind the face is filled with an insert configured to dampen a sound generated by the face upon hitting a golf ball and wherein the insert comprise at least one of a Thermoplastic Elastomers (TPE) and a Polyurethane (PU) foam. 
     
     
         50 . A method comprising:
 casting a shell comprising a hosel, a first periphery, and a back made of a non-layered material;   producing a face comprising a first layer comprising a Damascus Steel and a second layer comprising a bulk-solidifying amorphous alloy, and wherein the Damascus Steel is formed from plurality of layers, by repeated rolling and forging, wherein the plurality of layers comprises at least a first material and a second material, and wherein the face comprises a second periphery; and wherein the second layer is formed in a geometric shape comprising one of a honeycomb structure, an X shaped band, a plus shaped band, a circular bullseye shape, and a wire mesh;   generating a first thickness of a sweet spot of the face greater than a second thickness of other areas of the face;   attaching the second periphery to the first periphery of the shell via a welding, wherein the first periphery is attached along a boundary connecting a heel edge, a crown edge, a toe edge, and a sole edge of the second periphery; and   forming a cavity behind the face and within a body, the cavity extending rearward from the face to the back of the shell;   wherein the face comprises a decorative pattern formed from the Damascus Steel;   wherein a hardness of the face comprising the Damascus Steel on a Rockwell scale is at least 45 HRC; and   wherein the method is configured for manufacturing a golf club head of an iron type.   
     
     
         51 . The method of  claim 50 , wherein the shell is made using investment casting. 
     
     
         52 . The method of  claim 50 , wherein the shell comprises at least one of an AI 6061, a 431 stainless steel, and a 17-4PH stainless steel. 
     
     
         53 . The method of  claim 50 , wherein the plurality of layers is reduced from an initial thickness to a final thickness in a range of approximately 50 to 1.