Patent Publication Number: US-2012025592-A1

Title: Attack Tool

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. patent application Ser. No. 12/795,247, which is a continuation of U.S. patent application Ser. No. 12/041,880, which was a continuation of U.S. patent application Ser. No. 11/463,998 which is a continuation-in-part of U.S. patent application Ser. No. 11/463,990 which was filed on Aug. 11, 2006 and entitled An Attack Tool. U.S. patent application Ser. No. 11/463,990 is a continuation-in-part of U.S. patent application Ser. No. 11/463,975 which was filed on Aug. 11, 2006 and entitled An Attack Tool. U.S. patent application Ser. No. 11/463,975 is a continuation-in-part of U.S. patent application Ser. No. 11/463,962 which was filed on Aug. 11, 2006 and entitled An Attack Tool. All of these applications are herein incorporated by reference for all that it contains. 
    
    
     BACKGROUND OF THE INVENTION 
     Formation degradation, such as asphalt milling, mining, or excavating, may result in wear on attack tools. Consequently, many efforts have been made to extend the life of these tools. Examples of such efforts are disclosed in U.S. Pat. No. 4,944,559 to Sionnet et al., U.S. Pat. No. 5,837,071 to Andersson et al., U.S. Pat. No. 5,417,475 to Graham et al., U.S. Pat. No. 6,051,079 to Andersson et al., and U.S. Pat. No. 4,725,098 to Beach, all of which are herein incorporated by reference for all that they disclose. 
     BRIEF SUMMARY OF THE INVENTION 
     In one aspect of the invention, an attack tool has a wear-resistant base suitable for attachment to a driving mechanism. A first end of a generally frustoconical first cemented metal carbide segment bonded to the base. A second metal carbide segment is bonded to a second end of the first carbide segment at an interface opposite the base. The first end has a cross sectional thickness of about 0.250 to 0.750 inches and the second end has a cross sectional thickness of about 1 to 1.50 inches. The first cemented metal carbide segment also has a volume of 0.250 cubic inches to 0.600 cubic inches. In this disclosure, the abbreviation “HRc” stands for the Rockwell Hardness “C” scale, and the abbreviation “HK” stands for Knoop Hardness. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a cross-sectional diagram of an embodiment of attack tools on a rotating drum attached to a motor vehicle. 
         FIG. 2  is an orthogonal diagram of an embodiment of an attack tool and a holder. 
         FIG. 3  is an orthogonal diagram of another embodiment of an attack tool. 
         FIG. 4  is an orthogonal diagram of another embodiment of an attack tool. 
         FIG. 5  is a perspective diagram of a first cemented metal carbide segment. 
         FIG. 6  is an orthogonal diagram of an embodiment of a first cemented metal carbide segment. 
         FIG. 7  is an orthogonal diagram of another embodiment of a first cemented metal carbide segment. 
         FIG. 8  is an orthogonal diagram of another embodiment of a first cemented metal carbide segment. 
         FIG. 9  is an orthogonal diagram of another embodiment of a first cemented metal carbide segment. 
         FIG. 10  is an orthogonal diagram of another embodiment of a first cemented metal carbide segment. 
         FIG. 11  is a cross-sectional diagram of an embodiment of a second cemented metal carbide segment and a superhard material. 
         FIG. 12  is a cross-sectional diagram of another embodiment of a second cemented metal carbide segment and a superhard material. 
         FIG. 13  is a cross-sectional diagram of another embodiment of a second cemented metal carbide segment and a superhard material. 
         FIG. 14  is a cross-sectional diagram of another embodiment of a second cemented metal carbide segment and a superhard material. 
         FIG. 15  is a cross-sectional diagram of another embodiment of a second cemented metal carbide segment and a superhard material. 
         FIG. 16  is a cross-sectional diagram of another embodiment of a second cemented metal carbide segment and a superhard material. 
         FIG. 17  is a perspective diagram of another embodiment of an attack tool. 
         FIG. 18  is an orthogonal diagram of an alternate embodiment of an attack tool. 
         FIG. 19  is an orthogonal diagram of another alternate embodiment of an attack tool. 
         FIG. 20  is an orthogonal diagram of another alternate embodiment of an attack tool. 
         FIG. 21  is an exploded perspective diagram of another embodiment of an attack tool. 
         FIG. 22  is a schematic of a method of manufacturing an attack tool. 
         FIG. 23  is a perspective diagram of tool segments being brazed together. 
         FIG. 24  is a perspective diagram of an embodiment of an attack tool with inserts bonded to the wear-resistant base. 
         FIG. 25  is an orthogonal diagram of an embodiment of insert geometry. 
         FIG. 26  is an orthogonal diagram of another embodiment of insert geometry. 
         FIG. 27  is an orthogonal diagram of another embodiment of insert geometry. 
         FIG. 28  is an orthogonal diagram of another embodiment of insert geometry. 
         FIG. 29  is an orthogonal diagram of another embodiment of insert geometry. 
         FIG. 30  is an orthogonal diagram of another embodiment of insert geometry. 
         FIG. 31  is an orthogonal diagram of another embodiment of an attack tool. 
         FIG. 32  is a cross-sectional diagram of an embodiment of a shank. 
         FIG. 33  is a cross-sectional diagram of another embodiment of a shank. 
         FIG. 34  is a cross-sectional diagram of an embodiment of a shank. 
         FIG. 35  is a cross-sectional diagram of another embodiment of a shank. 
         FIG. 36  is an orthogonal diagram of another embodiment of a shank. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION AND THE PREFERRED EMBODIMENT 
     It will be readily understood that the components of the present invention, as generally described and illustrated in the Figures herein, may be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of embodiments of the methods of the present invention, as represented in the Figures is not intended to limit the scope of the invention, as claimed, but is merely representative of various selected embodiments of the invention. 
     The illustrated embodiments of the invention will best be understood by reference to the drawings, wherein like parts are designated by like numerals throughout. Those of ordinary skill in the art will, of course, appreciate that various modifications to the methods described herein may easily be made without departing from the essential characteristics of the invention, as described in connection with the Figures. Thus, the following description of the Figures is intended only by way of example, and simply illustrates certain selected embodiments consistent with the invention as claimed herein. 
       FIG. 1  is a cross-sectional diagram of an embodiment of an attack tool  101  on a rotating drum  102  attached to a motor vehicle  103 . The motor vehicle  103  may be a cold planer used to degrade man-made formations such as pavement  104  prior to the placement of a new layer of pavement, a mining vehicle used to degrade natural formations, or an excavating machine. Tools  101  may be attached to a drum  102  or a chain which rotates so the tools  101  engage a formation. The formation that the tool  101  engages may be hard and/or abrasive and cause substantial wear on tools  101 . The wear-resistant tool  101  may be selected from the group consisting of drill bits, asphalt picks, mining picks, hammers, indenters, shear cutters, indexable cutters, and combinations thereof. In large operations, such as pavement degradation or mining, when tools  101  need to be replaced the entire operation may cease while crews remove worn tools  101  and replace them with new tools  101 . The time spent replacing tools  101  may be costly. 
       FIG. 2  is an orthogonal diagram of an embodiment of a tool  101  and a holder  201 . A tool  101 /holder  201  combination is often used in asphalt milling and mining. A holder  201  is attached to a driving mechanism, which may be a rotating drum  102 , and the tool  101  is inserted into the holder  201 . The holder  201  may hold the tool  101  at an angle offset from the direction of rotation, such that the tool  101  optimally engages a formation. 
       FIG. 3  is an orthogonal diagram of an embodiment of a tool  101  with a first cemented metal carbide segment with a first volume. The tool  101  comprises a base  301  suitable for attachment to a driving mechanism, a first cemented metal carbide segment  302  bonded to the base  301  at a first interface  304 , and a second metal carbide segment  303  bonded to the first carbide segment  302  at a second interface  305  opposite the base  301 . The first cemented metal carbide segment  302  may comprise a first volume of 0.100 cubic inches to 2 cubic inches. Such a volume may be beneficial in absorbing impact stresses and protecting the rest of the tool  101  from wear. The first and/or second interfaces  304 ,  305  may be planar as well. The first and/or second metal carbide segments  302 ,  303  may comprise tungsten, titanium, tantalum, molybdenum, niobium, cobalt and/or combinations thereof. 
     Further, the tool  101  may comprise a ratio of the length  350  of the first cemented metal carbide segment  302  to the length of the whole attack tool  351  which is 1/10 to 1/2; preferably the ratio is 1/7 to 1/2.5. The wear-resistant base  301  may comprise a length  360  that is at least half of the tool&#39;s length  351 . 
       FIG. 4  is an orthogonal diagram of an embodiment of a tool with a first cemented metal carbide segment with a second volume, which is less than the first volume. This may help to reduce the weight of the tool  101  which may require less horsepower to move or it may help to reduce the cost of the attack tool. 
       FIG. 5  is a perspective diagram of a first cemented metal carbide segment. The volume of the first segment  302  may be 0.100 to 2 cubic inches; preferably the volume may be 0.350 to 0.550 cubic inches. The first segment  302  may comprise a height  501  of 0.2 inches to 2 inches; preferably the height  501  may be 0.500 inches to 0.800 inches. The first segment  302  may comprise an upper cross-sectional thickness  502  of 0.250 to 0.750 inches; preferably the upper cross-sectional thickness  502  may be 0.300 inches to 0.500 inches. The first segment  302  may also comprise a lower cross-sectional thickness  503  of 1 inch to 1.5 inches; preferably the lower cross-sectional thickness  503  may be 1.10 inches to 1.30 inches. The upper and lower cross-sectional thicknesses  502 ,  503  may be planar. The first segment  302  may also comprise a non-uniform cross-sectional thickness. Further, the segment  302  may have features such as a chamfered edge  505  and a ledge  506  to optimize bonding and/or improve performance. 
       FIGS. 6-10  are orthogonal diagrams of several embodiments of a first cemented metal carbide segment. Each figure discloses planar upper and lower ends  601 ,  602 . When the ends  601 ,  602  are bonded to the base  301  and second segment  303 , the resulting interfaces  304 ,  305  may also be planar. In other embodiments, the ends comprise a non-planar geometry such as a concave portion, a convex portion, ribs, splines, recesses, protrusions, and/or combinations thereof. 
     The first segment  302  may comprise various geometries. The geometry may be optimized to move cuttings away from the tool  101 , distribute impact stresses, reduce wear, improve degradation rates, protect other parts of the tool  101 , and/or combinations thereof. The embodiments of  FIGS. 6 and 7 , for instance, may be useful for protecting the tool  101 .  FIG. 6  comprises an embodiment of the first segment  302  without features such as a chamfered edge  505  and a ledge  506 . The bulbous geometry of the first segment  302  in  FIGS. 8 and 9  may be sacrificial and may extend the life of the tool  101 . A segment  302  as disclosed in  FIG. 10  may be useful in moving cuttings away from the tool  101  and focusing cutting forces at a specific point. 
       FIGS. 11-16  are cross-sectional diagrams of several embodiments of a second cemented metal carbide segment and a superhard material. The second cemented metal carbide segment  303  may be bonded to a superhard material  306  opposite the interface  304  between the first segment  302  and the base  301 . In other embodiments, the superhard material is bonded to any portion of the second segment. The interface  1150  between the second segment  303  and the superhard material  306  may be non-planar or planar. The superhard material  306  may comprise polycrystalline diamond, vapor-deposited diamond, natural diamond, cubic boron nitride, infiltrated diamond, layered diamond, diamond impregnated carbide, diamond impregnated matrix, silicon bonded diamond, or combinations thereof. The superhard material may be at least 4,000 HK and in some embodiments it may be 1 to 20000 microns thick. In embodiments, where the superhard material is a ceramic, the material may comprise a region  1160  (preferably near its surface  1151 ) that is free of binder material. The average grain size of a superhard ceramic may be 10 to 100 microns in size. Infiltrated diamond is typical made by sintering the superhard material adjacent a cemented metal carbide and allowing a metal (such as cobalt) to infiltrate into the superhard material. The superhard material may be a synthetic diamond comprising a binder concentration of 4 to 35 weight percent. 
     The second segment  303  and superhard material may comprise many geometries. In  FIG. 11  the second segment  303  has a relatively small surface area to bind with the superhard material reducing the amount of superhard material required and reducing the overall cost of the attack tool. In embodiments, where the superhard material is a polycrystalline diamond, the smaller the second carbide segment the cheaper it may be to produce large volumes of attack tool since more second segments may be placed in a high temperature high pressure apparatus at once. The superhard material  306  in FIG.  11  comprises a semi-round geometry. The superhard material in  FIG. 12  comprises a domed geometry. The superhard material  306  in  FIG. 13  comprises a mix of domed and conical geometry. Blunt geometries, such as those disclosed in  FIGS. 11-13  may help to distribute impact stresses during formation degradation, but cutting efficiency may be reduced. The superhard material  306  in  FIG. 14  comprises a conical geometry. The superhard material  306  in  FIG. 15  comprises a modified conical geometry, and the superhard material in  FIG. 16  comprises a flat geometry. Sharper geometries, such as those disclosed in  FIGS. 14 and 15 , may increase cutting efficiency, but more stress may be concentrated to a single point of the geometry upon impact. A flat geometry may have various benefits when placed at a positive cutting rake angle or other benefits when placed at a negative cutting rake angle. 
     The second segment  303  may comprise a region  1102  proximate the second interface  305  which may comprise a higher concentration of a binder than a distal region  1101  of the second segment  303  to improve bonding or add elasticity to the tool. The binder may comprise cobalt, iron, nickel, ruthenium, rhodium, palladium, chromium, manganese, tantalum, or combinations thereof. 
       FIG. 17  is a perspective diagram of another embodiment of a tool. Such a tool  101  may be used in mining. Mining equipment, such as continuous miners, may use a driving mechanism to which tools  101  may be attached. The driving mechanism may be a rotating drum  102 , similar to that used in asphalt milling, which may cause the tools  101  to engage a formation, such as a vein of coal or other natural resources. Tools  101  used in mining may be elongated compared to similar tools  101  like picks used in asphalt cold planars. 
       FIGS. 18-20  are cross-sectional diagrams of alternate embodiments of an attack tool. These tools are adapted to remain stationary within the holder  201  attached to the driving mechanism. Each of the tools  101  may comprise a base segment  301  which may comprise steel, a cemented metal carbide, or other metal. The tools  101  may also comprise first and second segments  302 ,  303  bonded at interfaces  304 ,  305 . The angle and geometry of the superhard material  306  may be altered to change the cutting ability of the tool  101 . Positive or negative rake angles may be used along with geometries that are semi-rounded, rounded, domed, conical, blunt, sharp, scoop, or combinations thereof. Also the superhard material may be flush with the surface of the carbide or it may extend beyond the carbide as well. 
       FIG. 21  is an exploded perspective diagram of an embodiment of an attack tool. The tool  101  comprises a wear-resistant base  301  suitable for attachment to a driving mechanism, a first cemented metal carbide segment  302  brazed to the wear-resistant base at a first interface  304 , a second cemented metal carbide segment  303  brazed to the first cemented metal carbide segment  302  at a second interface  305  opposite the wear-resistant base  301 , a shank  2104 , and a braze material  2101  disposed in the second interface  305  comprising 30 to 62 weight percent of palladium. Preferably, the braze material comprises 40 to 50 weight percent of palladium. 
     The braze material  2101  may comprise a melting temperature from 700 to 1200 degrees Celsius; preferably the melting temperature is from 800 to 970 degrees Celsius. The braze material may comprise silver, gold, copper nickel, palladium, boron, chromium, silicon, germanium, aluminum, iron, cobalt, manganese, titanium, tin, gallium, vanadium, phosphorus, molybdenum, platinum, or combinations thereof. The braze material  2101  may comprise 30 to 60 weight percent nickel, 30 to 62 weight percent palladium, and 3 to 15 weight percent silicon; preferably the first braze material  2101  may comprise 47.2 weight percent nickel, 46.7 weight percent palladium, and 6.1 weight percent silicon. Active cooling during brazing may be critical in some embodiments, since the heat from brazing may leave some residual stress in the bond between the second carbide segment and the superhard material. The second carbide segment  303  may comprise a length of 0.1 to 2 inches. The superhard material  306  may be 0.020 to 0.100 inches away from the interface  305 . The further away the superhard material  306  is, the less thermal damage is likely to occur during brazing. Increasing the distance  2104  between the interface  305  and the superhard material  306 , however, may increase the moment on the second carbide segment and increase stresses at the interface  305  upon impact. 
     The first interface  304  may comprise a second braze material  2102  which may comprise a melting temperature from 800 to 1200 degrees Celsius. The second braze material  2102  may comprise 40 to 80 weight percent copper, 3 to 20 weight percent nickel, and 3 to 45 weight percent manganese; preferably the second braze material  2101  may comprise 67.5 weight percent copper, 9 weight percent nickel, and 23.5 weight percent manganese. 
     Further, the first cemented metal carbide segment  302  may comprise an upper end  601  and the second cemented metal carbide segment may comprise a lower end  602 , wherein the upper and lower ends  601 ,  602  are substantially equal. 
       FIG. 22  is a schematic of a method of manufacturing a tool. The method  2200  comprises positioning  2201  a wear-resistant base  301 , first cemented metal carbide segment  302 , and second cemented metal carbide segment  303  in a brazing machine, disposing  2202  a second braze material  2102  at an interface  304  between the wear-resistant base  301  and the first cemented metal carbide segment  302 , disposing  2203  a first braze material  2101  at an interface  305  between the first and second cemented metal carbide segments  302 ,  303 , and heating  2204  the first cemented metal carbide segment  302  to a temperature at which both braze materials melt simultaneously. The method  2200  may comprise an additional step of actively cooling the attack tool, preferably the second carbide segment  303 , while brazing. The method  2200  may further comprise a step of air-cooling the brazed tool  101 . 
     The interface  304  between the wear-resistant base  301  and the first segment  302  may be planar, and the interface  305  between the first and second segments  302 ,  303  may also be planar. Further, the second braze material  2102  may comprise 50 to 70 weight percent of copper, and the first braze material  2101  may comprise 40 to 50 weight percent palladium. 
       FIG. 23  is a perspective diagram of tool segments being brazed together. The attack tool  101  may be assembled as described in the above method  2200 . Force, indicated by arrows  2350  and  2351 , may be applied to the tool  101  to keep all components in line. A spring  2360  may urge the shank  2104  upwards and positioned within the machine (not shown). There are various ways to heat the first segment  302 , including using an inductive coil  2301 . The coil  2301  may be positioned to allow optimal heating at both interfaces  304 ,  305  to occur. Brazing may occur in an atmosphere that is beneficial to the process. Using an inert atmosphere may eliminate elements such as oxygen, carbon, and other contaminates from the atmosphere that may contaminate the braze material  2101 ,  2102 . 
     The tool may be actively cooled as it is being brazed. Specifically, the superhard material  306  may be actively cooled. A heat sink  2370  may be placed over at least part of the second segment  303  to remove heat during brazing. Water or other fluid may be circulated around the heat sink  2370  to remove the heat. The heat sink  2370  may also be used to apply a force on the tool  101  to hold it together while brazing. 
       FIG. 24  is a perspective diagram of an embodiment of a tool with inserts in the wear-resistant base. An attack tool  101  may comprise a wear-resistant base  301  suitable for attachment to a driving mechanism, the wear-resistant base comprising a shank  2104  and a metal segment  2401 ; a cemented metal carbide segment  302  bonded to the metal segment  2401  opposite the shank  2104 ; and at least one hard insert  2402  bonded to the metal segment  2401  proximate the shank wherein the insert  2402  comprises a hardness greater than 60 HRc. The metal segment  2401  may comprise a hardness of 40 to 50 HRc. The metal segment  2401  and shank  2104  may be made from the same piece of material. 
     The insert  2402  may comprise a material selected from the group consisting of diamond, natural diamond, polycrystalline diamond, cubic boron nitride, vapor-deposited diamond, diamond grit, polycrystalline diamond grit, cubic boron nitride grit, chromium, tungsten, titanium, molybdenum, niobium, a cemented metal carbide, tungsten carbide, aluminum oxide, zircon, silicon carbide, whisker reinforced ceramics, diamond impregnated carbide, diamond impregnated matrix, silicon bonded diamond, or combinations thereof as long as the hardness of the material is greater than 60 HRc. Having an insert  2402  that is harder than the metal segment  2401  may decrease the wear on the metal segment  2401 . The insert  2402  may comprise a cross-sectional thickness of 0.030 to 0.500 inches. The insert  2402  may comprise an axial length  2451  less than an axial length  2450  of the metal segment  2402 , and the insert  2402  may comprise a length shorter than a circumference  2470  of the metal segment  2401  proximate the shank  2104 . The insert  2402  may be brazed to the metal segment  2401 . The insert  2402  may be a ceramic with a binder comprising 4 to 35 weight percent of the insert. The insert  2402  may also be polished. 
     The base  301  may comprise a ledge  2403  substantially normal to an axial length of the tool  101 , the axial length being measured along the axis  2405  shown. At least a portion of a perimeter  2460  of the insert  2402  may be within 0.5 inches of the ledge  2403 . If the ratio of the length  350  of the first cemented metal carbide segment  302  to the length of the whole attack tool  351  may be 1/10 to 1/2, the wear-resistant base  301  may comprise as much as 9/10 to 1/2 of the tool  101 . An insert&#39;s axial length  2451  may not exceed the length of the wear-resistant base&#39;s length  360 . The insert&#39;s perimeter  2460  may extend to the edge  2461  of the wear-resistant base  301 , but the first carbide segment  302  may be free of an insert  2402 . The insert  2402  may be disposed entirely on the wear-resistant base  301 . Further, the metal segment  2401  may comprise a length  2450  which is greater than the insert&#39;s length  2451 ; the perimeter  2460  of the insert  2402  may not extend beyond the ledge  2403  of the metal segment  2401  or beyond the edge of the metal segment  2461 . 
     Inserts  2402  may also aid in tool rotation. Attack tools  101  often rotate within their holders upon impact which allows wear to occur evenly around the tool  101 . The inserts  2402  may be angled such so that it cause the tool  101  to rotate within the bore of the holder. 
       FIGS. 25-30  are orthogonal diagrams of several embodiments of insert geometries. The insert  2402  may comprise a generally circular shape, a generally rectangular shape, a generally annular shape, a generally spherical shape, a generally pyramidal shape, a generally conical shape, a generally accurate shape, a generally asymmetric shape, or combinations thereof. The distal most surface  2501  of the insert  2402  may be flush with the surface  2502  of the wear-resistant base  301 , extend beyond the surface  2502  of the wear-resistant base  301 , be recessed into the surface  2502  of the wear-resistant base, or combinations thereof. An example of the insert  2402  extending beyond the surface  2502  of the base  301  is seen in if  FIG. 24 .  FIG. 25  discloses generally rectangular inserts  2402  that are aligned with a central axis  2405  of the tool  101 . 
       FIG. 26  discloses an insert  2402  comprising an axial length  2451  forming an angle  2602  of 1 to 75 degrees with an axial length  2603  of the tool  101 . The inserts  2402  may be oblong. 
       FIG. 27  discloses a circular insert  2402  bonded to a protrusion  2701  formed in the base. The insert  2402  may be flush with the surface of the protrusion  2701 , extend beyond the protrusion  2701 , or be recessed within the protrusion  2701 . A protrusion  2701  may help extend the insert  2402  so that the wear is decreased as the insert  2402  takes more of the impact.  FIGS. 28-30  disclose segmented inserts  2402  that may extend considerably around the metal segment&#39;s circumference  2470 . The angle formed by insert&#39;s axial length  2601  may also be 90 degrees from the tool&#39;s axial length  2603 . 
       FIG. 31  is an orthogonal diagram of another embodiment of a tool. The base  301  of an attack tool  101  may comprise a tapered region  3101  intermediate the metal segment  2401  and the shank  2104 . An insert  2402  may be bonded to the tapered region  3101 , and a perimeter of the insert  2402  may be within 0.5 inches of the tapered region  3101 . The inserts  2402  may extend beyond the perimeter  3110  of the tool  101 . This may be beneficial in protecting the metal segment. A tool tip  3102  may be bonded to a cemented metal carbide, wherein the tip may comprise a layer selected from the group consisting of diamond, natural diamond, polycrystalline diamond, cubic boron nitride, infiltrated diamond, or combinations thereof. In some embodiments, a tip  3102  is formed by the first carbide segment. The first carbide segment may comprise a superhard material bonded to it although it is not required. 
       FIGS. 32 and 33  are cross-sectional diagrams of embodiments of the shank. An attack tool may comprise a wear-resistant base suitable for attachment to a driving mechanism, the wear-resistant base comprising a shank  2104  and a metal segment  2401 ; a cemented metal carbide segment bonded to the metal segment; and the shank comprising a wear-resistant surface  3202 , wherein the wear-resistant surface  3202  comprises a hardness greater than 60 HRc. 
     The shank  2104  and the metal segment  2401  may be formed from a single piece of metal. The base may comprise steel having a hardness of 35 to 50 HRc. The shank  2104  may comprise a cemented metal carbide, steel, manganese, nickel, chromium, titanium, or combinations thereof. If a shank  2104  comprises a cemented metal carbide, the carbide may have a binder concentration of 4 to 35 weight percent. The binder may be cobalt. 
     The wear-resistant surface  3202  may comprise a cemented metal carbide, chromium, manganese, nickel, titanium, hard surfacing, diamond, cubic boron nitride, polycrystalline diamond, diamond impregnated carbide, diamond impregnated matrix, silicon bonded diamond, deposited diamond, aluminum oxide, zircon, silicon carbide, whisker reinforced ceramics, or combinations thereof. The wear-resistant surface  3202  may be bonded to the shank  2104  though the processes of electroplating, cladding, electroless plating, thermal spraying, annealing, hard facing, applying high pressure, hot dipping, brazing, or combinations thereof. The surface  3202  may comprise a thickness  3220  of 0.001 to 0.200 inches. The surface  3202  may be polished. The shank  2104  may also comprise layers. A core  3201  may comprise steel, surrounded by a layer of another material, such as tungsten carbide. There may be one or more intermediate layers  3310  between the core  3201  and the wear-resistant surface  3202  that may help the wear-resistant surface  3202  bond to the core. The wear-resistant surface  3202  may also comprise a plurality of layers  3201 ,  3310 ,  3202 . The plurality of layers may comprise different characteristics selected from the group consisting of hardness, modulus of elasticity, strength, thickness, grain size, metal concentration, weight, and combinations thereof. The wear-resistant surface  3202  may comprise chromium having a hardness of 65 to 75 HRc. 
       FIGS. 34 and 35  are orthogonal diagrams of embodiments of the shank. The shank  2401  may comprise one or more grooves  3401 . The wear-resistant surface  3202  may be disposed within a groove  3401  formed in the shank  2104 . Grooves  3401  may be beneficial in increasing the bond strength between the wear-resistant surface  3202  and the core  3201 . The bond may also be improved by swaging the wear-resistant surface  3202  on the core  3201  of the shank  2104 . Additionally, the wear-resistant surface  3202  may comprise a non-uniform diameter  3501 . The non-uniform diameter  3501  may help hold a retaining member (not shown) while the tool  101  is in use. The entire cross-sectional thickness  3410  of the shank may be harder than 60 HRc. In some embodiments, the shank may be made of a solid cemented metal carbide, or other material comprising a hardness greater than 60 HRc. 
       FIG. 36  is an orthogonal diagram of another embodiment of the shank. The wear-resistant surface  3202  may be segmented. Wear-resistant surface  3202  segments may comprise a height less than the height of the shank  2104 . The tool  101  may also comprise a tool tip  3102  which may be bonded to the cemented metal carbide segment  302  and may comprise a layer selected from the group consisting of diamond, natural diamond synthetic diamond, polycrystalline diamond, infiltrated diamond, cubic boron nitride, or combinations thereof. The polycrystalline diamond may comprise a binder concentration of 4 to 35 weight percent.