Retention system

Abstract

A retention assembly, comprises a carbide bolster comprising a cavity formed in its base end. A shaft comprises an inserted end disposed within the cavity. The shaft is disposed within a hollow shank which comprises a first end contacting the bolster and a loaded end in mechanical communication with the shaft. The inserted end is interlocked to an inner surface of the cavity through a casting.

Description

BACKGROUND OF THE INVENTION

In the road construction and mining industries, rocks and pavement are degraded using attack tools. Often, a drum with an array of attack tools attached to it may be rotated and moved so that attack tools engage a paved surface or rock to be degraded. Because attack tools engage materials that may be abrasive, attack tools may be susceptible to wear.

U.S. Pat. No. 6,733,087 to Hall et al., which is herein incorporated by reference for all that it contains, discloses an attack tool for working natural and man-made materials that is made up of one or more segments, including a steel alloy base segment, an intermediate carbide wear protector segment, and a penetrator segment comprising a carbide substrate that is coated with a super hard material. The segments are joined at continuously curved interfacial surfaces that may be interrupted by grooves, ridges, protrusions, and posts. At least a portion of the curved surfaces vary from one another at about their apex in order to accommodate ease of manufacturing and to concentrate the bonding material in the region of greatest variance.

Examples of degradation assemblies from the prior art are disclosed in U.S. Pat. No. 6,824,225 to Stiffler; U.S. Patent Publication No. 2005/0173966 to Mouthaan; U.S. Pat. No. 6,692,083 to Latham; U.S. Pat. No. 6,786,557 to Montgomery, Jr.; U.S. Patent Publication No. 2003/0230926 to Mondy; U.S. Pat. No. 4,932,723 to Mills; U.S. Patent Publication No. 2002/0175555 to Merceir; U.S. Pat. No. 6,854,810 Montgomery, Jr.; and U.S. Pat. No. 6,851,758 to Beach, which areall herein incororated by reference for all they contain.

Pub. No. 2002/0175555 to Merceir U.S. Pat. No. 6,854,810 to Montgomery, Jr.; and U.S. Pat. No. 6,851,758 to Beach, which are all herein incorporated by reference for all they contain.

BRIEF SUMMARY OF THE INVENTION

In one aspect of the invention a retention assembly has a carbide bolster comprising a cavity formed in its base end. A shaft comprises an inserted end disposed within the cavity. The shaft is disposed within a hollow shank which comprises a first end contacting the bolster and a loaded end in mechanical communication with the shaft and the inserted end is brazed to an inner surface of the cavity.

The shaft may be in mechanical communication with the loaded end through a threaded nut. The threaded nut may engage a shoulder of the shank. The brazed joint may comprise a braze material comprising copper, brass, lead, tin, silver or combinations thereof. The inserted end of the shaft may be interlocked inside the cavity. The shaft, the carbide bolster and the shank may be coaxial. The inserted end of the shaft may be brazed with the inner surface of the cavity of the bolster. The inserted end of the shaft may be adapted to compliment the ceiling of the bolster. The cavity may comprise a concave surface adapted to receive the shaft. The retention assembly may be incorporated into drill bits, shear bits, cone crushers, picks, hammer mills or combinations thereof. The cavity of the bolster may comprise a thermal expansion relief groove. The interface between the inserted end of the shaft and the bolster may be non-planar. The inserted end of the shaft may comprise a 1 to 15 degree taper. The inserted end of the shaft may comprise at least one thermal expansion relief groove. The thermal expansion relief grooves in the inserted end of the shaft may be adapted to receive the thermal expansion relief grooves in the cavity of the bolster. The inserted end of the shaft may be brazed to a top of the cavity. A tip made of carbide and diamond may be brazed to the bolster. An insert may be brazed into the cavity and the insert may retain the inserted end of the shaft. The insert and the inserted end may comprise a rounded interface. The retention assembly may be incorporated into a driving mechanism, a drum, a chain, or combinations thereof. The bolster may comprise an assembly brazed into the cavity and assembly may comprise a pocket adapted to hold the inserted portion of the shaft.

In another aspect of the invention a retention assembly has a carbide bolster comprising a cavity formed in its base end. A shaft comprises an inserted end disposed within the cavity. The shaft is disposed within a hollow shank which comprises a first end contacting the bolster and a loaded end in mechanical communication with the shaft and the inserted end is interlocked within the geometry of the cavity by a casting.

The cast material may comprise metals like zinc, aluminum, magnesium; thermosetting plastics, Bakelite, melamine resin, polyester resin, vulcanized rubber or combination thereof. The shaft may be in mechanical communication with the loaded end through a threaded nut. The threaded nut may engage a shoulder of the shank. The inserted end of the shaft may comprise a 1 to 15 degree taper. The inserted end of the shaft may comprise an increase in diameter. The shaft, the carbide bolster and the shank may be coaxial. The inserted end of the shaft may compromise at least one groove formed in its surface. The retention assembly may be incorporated into drill bits, shear bits, hammer mills, cone crushers, or combinations thereof.

The inserted end of the shaft may compromise a shaft geometry adapted to interlock with the casting. The inner surface of the cavity of the bolster may comprise a cavity geometry adapted to interlock with the casting. The cavity geometry may comprise a taper narrowing towards an opening of the cavity formed in the base end. The diameter of the opening of the cavity formed in the base end is slightly smaller than the diameter of a tapered end of the shaft. The cavity geometry may comprise a lip. The inserted end of the shaft may be in contact with the cavity of the bolster. A tip of carbide and diamond may be brazed to the bolster. The retention assembly may be incorporated into a driving mechanism, a drum, a chain, a rotor, or combination thereof. The casting may submerge at least the tapered end of the shaft.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional diagram of an embodiment of a plurality of picks suspended underside of a pavement milling machine.

FIG. 2 is a cross-sectional diagram of an embodiment of a pick.

FIG. 3 is an exploded diagram of an embodiment of a pick.

FIG. 4 is a cross-sectional diagram of an embodiment of a pick.

FIG. 5 is a cross-sectional diagram of another embodiment of a pick.

FIG. 6 is a cross-sectional diagram of another embodiment of a pick.

FIG. 7 is a cross-sectional diagram of another embodiment of a pick.

FIG. 8 is a cross-sectional diagram of another embodiment of a pick.

FIG. 9 is a cross-sectional diagram of another embodiment of a pick.

FIG. 10 is a cross sectional diagram of an embodiment of an insert brazed in a cavity.

FIG. 11 is a perspective diagram of another embodiment of an insert brazed in the cavity.

FIG. 12 is a cross-sectional diagram of another embodiment of a pick.

FIG. 13 is a cross-sectional diagram of an embodiment of a casting process.

FIG. 14 is a cross-sectional diagram of another embodiment of a pick.

FIG. 15 is a cross-sectional diagram of another embodiment of a pick.

FIG. 16 is a cross-sectional diagram of another embodiment of a pick.

FIG. 17 is a cross-sectional diagram of another embodiment of a pick.

FIG. 18 is a cross-sectional diagram of an embodiment of a retention assembly.

FIG. 19 is a cross-sectional diagram of another embodiment of a pick.

FIG. 20 is a cross-sectional diagram of another embodiment of a pick.

FIG. 21 is a cross-sectional diagram of another embodiment of a pick.

FIG. 22 is a cross-sectional diagram of another embodiment of a pick.

FIG. 23 is a cross-sectional diagram of another embodiment of a pick.

FIG. 24 is a cross-sectional diagram of another embodiment of a pick.

FIG. 25 is a cross-sectional diagram of another embodiment of a pick.

FIG. 26 is a cross-sectional diagram of another embodiment of a pick.

FIG. 27 is a cross-sectional diagram of another embodiment of a pick.

FIG. 28 is a cross-sectional diagram of another embodiment of a pick.

FIG. 29 is a cross-sectional diagram of another embodiment of a pick.

FIG. 30 is a cross-sectional diagram of an embodiment of a trencher.

FIG. 31 is a cross-sectional diagram of another embodiment of a trencher.

FIG. 32 is a cross-sectional diagram of an embodiment of a percussion bit.

FIG. 33 is a cross-sectional diagram of an embodiment of a fixed cutter bit.

FIG. 34 is a cross-sectional diagram of an embodiment of a roller cone.

FIG. 35 is a cross-sectional diagram of another embodiment of a retention assembly.

FIG. 36 is a cross-sectional diagram of another embodiment of a retention assembly.

FIG. 37 is a cross-sectional diagram of another embodiment of a retention assembly.

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 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 a plurality of picks 101 attached to a rotating drum 102 connected to the underside of a pavement milling machine 103. The milling machine 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. Picks 101 may be attached to the drum 102 bringing the picks 101 into engagement with the formation.

FIG. 2 is an orthogonal diagram of an embodiment of a pick 101a. The pick 101a comprises a cemented metal carbide bolster 201a attached to a hollow shank 202a at a base end 203a of the carbide bolster 201a. The hollow shank 202a has a bore 240 with a diameter 260. The carbide bolster 201a may comprise tungsten carbide, calcium carbide, silicon carbide, cementite, boron carbide, tantalum carbide, titanium carbide or combination thereof. The shank 202a may be substantially cylindrical and/or tapered.

An impact tip 205 may comprise a super hard material 207 bonded to a carbide substrate 305a at a non-planar interface 210. Preferably the carbide substrate 305a has an axial thickness less than 6 mm. In some embodiments, the carbide substrate 305a ranges between 10 and 1 mm. The superhard material 207 may be at least 0.100 inches thick axially, in some embodiments it may be over 0.250 inches. The superhard material 207 may be formed in a substantially conical shape.

Typically the carbide substrate 305a of the impact tip 205 is brazed to the carbide bolster 201a at a planar interface 306. The impact tip 205 and the carbide bolster 201 may be brazed together with a braze material comprising a melting temperature from 700 to 1200 degrees Celsius. The super hard material 207 may be bonded to the carbide substrate 305a through a high-temperature/high-pressure process (HTHP).

The super hard material 207 may comprise diamond, polycrystalline diamond with a binder concentration of 1 to 40 weight percent, cubic boron nitride, refractory metal bonded diamond, silicon bonded diamond, layered diamond, infiltrated diamond, thermally stable diamond, natural diamond, vapor deposited diamond, physically deposited diamond, diamond impregnated matrix, diamond impregnated carbide, monolithic diamond, polished diamond, course diamond, fine diamond, nonmetal catalyzed diamond, cemented metal carbide, chromium, titanium, aluminum, tungsten, or combinations thereof.

A cavity 307a may be formed at the base end 203a of the bolster 201a. An inserted end 204a of a shaft 301a may be inserted into the cavity 307a. An other end 250 of the shaft 301a may be in mechanical communication with a loaded end 251 of the shank 202a. The other end 250a of the shaft 301a may comprise at least one thread 252 adapted to receive a threaded nut 302a. A threaded nut diameter 220 may be bigger than a shaft diameter 230 but smaller than the bore diameter 260.

The inserted end 204a of the shaft 301a may be brazed within the cavity 307a of the carbide bolster 201a. Preferably, a head 270 of the inserted end 204a comprises a geometry that compliments a geometry of the cavity 307a. Preferably, the head 270 of the inserted end 204a is brazed directly to a ceiling 253a of the cavity 307a. In other embodiments, the shaft 301a is brazed to a side wall 254 of the cavity 307a.

Referring now to the embodiment of FIG. 3, a carbide substrate 305b and a carbide bolster 201b may be brazed together at high temperature at the same time an inserted end 204b of a shaft 301b is brazed to a cavity 307b . The shaft 301b and the cavity 307b may be brazed at a non-planar interface 310. In some embodiments, the braze joints may be brazed at different times. In some embodiments, both braze joints utilize substantially similar braze materials 410a and 410b.

After brazing the inserted end 204b of the shaft 301 into the cavity 307b, an other end 250b of the shaft 301b may be tensioned through a hollow shank 202b and anchored while under tension with a threaded nut 302b. This tension loads the inserted end 204b of the shaft 301b and snuggly holds the carbide bolster 201b against the hollow shank 202b.

In the embodiment of FIG. 4, an inserted end 204c of a shaft 301c is tapered at shaft taper 403, which is adapted to abut a cavity taper 401 of a cavity 402. The shaft taper 403 and the cavity taper 401 may be brazed together.

In the embodiment of FIG. 5, an inserted end 204d of a shaft 301d is brazed to a ceiling 253d of a cavity 307d. A diameter 501 of the inserted end 204d is larger than a diameter 502 of an opening constricted by a protruding lip 601 formed in the cavity 307d. The geometry of the inserted end 204d is adapted to flex upon insertion and snap out once past the lip 601. The inserted end 204d of the shaft 301d may be interlocked inside the cavity 307d of the carbide bolster 201d. The geometry of the inserted end 204d of the shaft 301d may allow enough space for thermal expansion while brazing the inserted end 301d to the cavity 307d.

Referring now to the embodiment of FIG. 6, an inserted end 204e of the shaft 301e may comprise at least one relief groove 650 to allow space for thermal expansion during brazing. This may reduce residual stress that may develop during brazing.

Referring now to the embodiment of FIG. 7, a ceiling 253f of the cavity 307f of a carbide bolster 201f may comprise at least one relief groove 701f to allow for thermal expansion during brazing. The relief groove 701f may reduce residual stress that may develop during brazing. An inserted end 204f of a shaft 301f may be partially brazed to the ceiling 253f of the cavity 307f of the carbide bolster 201f.

In FIG. 8 another embodiment of the invention is disclosed in which a pick 101g may comprise at least one groove 701g in a ceiling 253g of a cavity 307g of a carbide bolster 201g adapted to receive protrusions 803 in an inserted end 204g of a shaft 301g. The ceiling 253g may be irregular and non-planar. The grooves 701g may form an interlocking mechanism with the protrusion 803. The grooves 701g may increase the surface area of the inserted end 204g and ceiling 253g allowing a larger braze joint.

FIG. 9 is a cross-sectional diagram of another embodiment of a pick 101h. A relief opening 802 may be formed in an inserted end 204h of a shaft 301h. The purpose of the relief opening 802 may be to allow enough space for thermal expansion while brazing.

Referring now to FIG. 10, an insert 506i may be brazed into a cavity 307i of a carbide bolster 201i. The insert 506i may be adapted to retain an inserted end 204i of a shaft 301i, preferably in ball and socket type of joint, although in some embodiments the joint may be tapered or interlocked. A cap 505 may be used in some embodiment to prevent a brazing material from flowing into the insert 506i and interfering with the joint. The solidification of the brazing material may restrict the compliancy of the joint during a bending moment induced in the carbide bolster 201i while in operation and create stress risers. The insert 506i and the inserted end 204i of the shaft 301i may comprise a rounded interface.

In FIG. 11, another embodiment of an insert 506j brazed within a cavity is shown.

FIG. 12 is a cross-sectional diagram of another embodiment of a pick 101k. An inserted end 204k of a shaft 301k may be interlocked within a cavity 307k of a carbide bolster 201k by a cast material 1201. The cast material 1201 may comprise zinc, a braze material, a plastic, lead, or combinations thereof. Zinc may be the preferred cast material since zinc will not significantly bond to the carbide and zinc demonstrates a high compressive strength. In some embodiment a non-wetting agent may be applied to a head 270k of the shaft 301k to prevent the zinc from forming a strong bond with the head 270k of the shaft 301k.

In FIG. 13, a cross-sectional diagram of an embodiment depicting a casting process is shown. A tapered inserted end 2041 of a shaft 3011 may be brought into a cavity 3071 and molten cast material 4011 may be poured inside the cavity 3071. The molten cast material 4011 may be left to be cooled and solidify. The cooling rate may vary according to the cast material 4011. The rate at which a cast material 4011 cools may affect the microstructure, quality, and properties of the cast material 4011 and the mechanical interlocking of the cast material 4011 with the shaft 3011 and the geometry of the cavity 3071. The geometry of the cavity 3071 of the carbide bolster 2011 may provide additional support in keeping the inserted end 2041 of the shaft 3011 interlocked within the cavity 3071.

In other embodiments, casting material granules, balls, shavings, segments, dust or combinations thereof may be placed in the cavity 3071 with the inserted end 2041 of the shaft 3011 and melted in place. The cast material 4011 may be heated in an oven, or a heating source such as a torch or radiant heater may be applied within the cavity 3071 or applied to the outside of the carbide bolster 2011.

FIG. 14 is another embodiment of pick 101m. A shaft 301m is disposed with a cavity 307m with cast material 401m cast within the cavity 307m proximate the shaft 301m. The shaft 301m includes a first diameter 1402 and a second diameter 1403 greater than said first diameter 1402 with the second diameter 1403 adapted to substantially contact an inner diameter 230m of a hollow shank 202m.

FIG. 15 is a cross-sectional diagram of another embodiment of a pick 101n. An inserted end 204n of a shaft 301n may or may not touch a ceiling 253n of the cavity 307n. The cast material 401n may form around an entire surface of a head 270n of the inserted end 204n.

In the embodiment of FIG. 16, an inserted end 204o of a shaft 301o may be tapered to increase its surface area with the cast material 401o. In some embodiments, the taper is gradual and distributes the load substantially equally across an interface between the cast material 401o and the inserted end 104o. Another benefit of casting the cast material 401o with a shaft 301o in place is distributing the loads across substantially the entire inner surface of a cavity 307o.

Referring now to the embodiment of FIG. 17, an inserted end 204p may comprise at least one groove 1001, and may be tapered. The groove 1001 may increase the grip between the inserted end 204p and the cast material 401p.

FIG. 18 is a cross-sectional diagram of an embodiment of a degradation assembly inserted into a blind hole 2020 of a tool, such as a fixed cutter drill bit, percussion bit, roller cone bit, miller, crusher and/or mill. An inserted end 204q of a shaft 301q may be brought together with a cavity 307q of a bolster 201q by a cast material 401q.

FIG. 19 is another embodiment of a pick 101r. The carbide bolster 201r comprises a first segment 2000a and a second segment 2001a. Since carbide is a brittle material and shaft 301r is tensioned and therefore loading at least a portion of the carbide bolster 201r, a thick carbide lip 2002 is incorporated into this embodiment. The carbide bolster 201r is formed in two segments to allow insertion of an other end 250r of a shaft 301r through the carbide bolster 201r opposite a base end 203r of the carbide bolster 201r. The shaft 301r includes a shaft diameter 2022 and an inserted end diameter 2021 with a portion 2023 having an diameter 2023a greater than the shaft diameter 2022 and less than the inserted end diameter 2021 disposed between the shaft diameter 2022 and the inserted end diameter 2021. The portion 2023 interlocks with the lip 2002 of the first segment 2000a. The second segment 2001a of the carbide bolster 201 is brazed to the first segment 2000a after inserted end 204r is in place. Both the first segment 2000a and the second segment 2002a are made of similar materials reducing thermal stresses that are common in traditional picks.

In some embodiments, the second carbide segment 2001a overhangs the first segment 2000a, directing debris away from a braze joint 2005 during a milling operation. The interface between the lip 2002 of the carbide bolster 201r and the inserted end 204r of the shaft 301r in some embodiments forms a joint that allows the inserted end 204r to swivel within a cavity 307r. This reduces the transfer of stress induced in the carbide bolster 201r during a bending moment to the shaft 301r.

In some embodiments, the shaft 301r may be casted, brazed, bonded, or combinations thereof in the cavity 307r after insertion.

In some embodiments, the inserted end 204r may be brazed in place while the first bolster segment 2000a and the second bolster segment 2001a are brazed together. In other embodiments, while brazing the first segment 2000a and the second 2001a together the flow of the braze material is controlled to prevent the braze material from interfering with the shaft 301r. In some embodiments, the inserted end 204r of the shaft 301r is coated with boron nitride or another non-wetting agent to prevent the braze material from bonding to the inserted end 204r of the shaft 301r.

In some embodiments, the first segment 2000a and the second 2001a may be made of different carbide grades. The first segment 2000a may comprise a more wear resistant carbide grade while the second segment 2001a may comprise a tougher grade or vice versa.

The embodiment of FIG. 20 discloses an embodiment of a pick 101s that includes a carbide bolster 2201a including a rearward sloping braze joint 2006 between a first carbide segment 2000b and a second carbide segment 2001b . The rearward sloping braze joint 2006 extends towards a base end 2203a of a carbide bolster 2201a as the rearward sloping braze joint 2006 extends from a cavity 2307a of the carbide bolster 2201b .

The embodiment of FIG. 21 discloses an embodiment of a pick 101t that includes a carbide bolster 2201b including a frontward sloping braze joint 2007 between a first carbide segment 2000c and a second carbide segment 2001c in which the frontward sloping braze joint 2007 extends away from a base end 2203b of the carbide bolster 2201b as the frontward sloping braze joint 2007 extends from a cavity 2307b of the carbide bolster 2201b.

The embodiment of FIG. 22 discloses an embodiment of a pick 101u that includes a third bolster segment 2008, in addition to a first bolster segment 2000d and a second bolster segment 2001d.

In some embodiments, a space within a cavity 307s may be lubricated. One such embodiment is disclosed in FIG. 23 where a port 2009 is formed in a shaft 301s to accommodate a flow of lubricate lubricant 2020 from a lubricant reservoir to the cavity 307s.

FIG. 24 discloses an embodiment in which a first carbide segment 2030 and a second carbide segment 2040 are bonded to one another along an axial braze joint 2010.

FIG. 25 discloses a wear resistant coating 2011 deposited on an inserted end 204t to prevent wear.

FIG. 26 discloses an embodiment including a braze joint 2012 between a lip 2002b and an underside 2013 of an inserted end 204u of a shaft 301u.

FIG. 27 discloses an embodiment in which a bolster 201v is adapted to rotate around an inserted end 204v of a shaft 301v. In such embodiments, an o-ring 2014 may be placed between a hollow shank 202v and a base end 203v of the bolster 201v. The shaft 301v may be press fit into the hollow shank 202v. In some embodiments a shaft may protrude out of a solid shank (not shown). Wear resistant material and lubricants may be applied to the rotating surfaces. In FIG. 27, the shaft 301v is press fit within the hollow shank 202v.

The embodiment of FIG. 28 illustrates a shaft 301w that is tensioned and secured through a threaded nut 2015 on a loaded end 251w of a hollow shank 202w. A hardened washer 2016 is attached to the hollow shank 202w abutting a base end 203w of a bolster 201w to provide a bearing surface on which the bolster 201w may rotate. The bolster 201w also forms an overhang 2017 over the hollow shank 202w to direct debris away from the rotating interface 2018.

FIG. 29 is another embodiment of a segmented bolster 201x with an inserted end 204x of a shank 301x cast in place.

FIG. 30 is a perspective diagram of an embodiment of a pick 101v, such as pick 101 of FIG. 1, on a rock wheel trenching machine 1301.

FIG. 31 discloses an embodiment of a pick, such as pick 101 of FIG. 1 on a chain trenching machine 1401. The pick may be placed on a chain that rotates around an arm 1402 of the chain trenching machine 1401.

In FIG. 32, a cross-sectional diagram of an embodiment of a percussion bit 1400 having a bit body 1401 with slots 1402 for receiving the picks 100z. The picks 100z may be anchored in the slots 1402 through a press fit, barbs, hooks, snap rings, or combinations thereof.

FIG. 33 discloses another embodiment with picks 3100 in a fixed cutter bit 1500.

FIG. 34 discloses another embodiment with picks 4100 in a cone 5004 of a roller cone bit.

FIG. 35 is a cross-sectional diagram of another embodiment of the retention assembly. The retention assembly 2600a may be used to bring two parts together such as two parts 2500 and 2501 of a chair.

Referring now to FIG. 36, a retention assembly 2006b may be used to connect two blocks 5005 and 5006 together.

In FIG. 37 a retention assembly 2006c may be used to attach a block 2601 with the other block 2602.

Whereas the present invention has been described in particular relation to the drawings attached hereto, it should be understood that other and further modifications apart from those shown or suggested herein, may be made within the scope and spirit of the present invention.

Claims

1. A retention assembly, comprising: a carbide bolster having a base end, the base end including a cavity formed therein;a shank including a first end, a loaded end, and a bore extending from said first end to said loaded end, said first end being in contact with said carbide bolster;a shaft disposed within said bore including an inserted end disposed within said cavity and an other end in mechanical communication with said loaded end; anda cast material disposed within said cavity, said cast material interlocking said inserted end within said cavity.

2. The retention assembly of claim 1, wherein said cast material is selected from the group consisting of zinc, aluminum, magnesium, thermosetting plastics, melamine resin, polyester resin polyimide, or vulcanized rubber.

3. The retention assembly of claim 1, further comprising a nut having threads, wherein said shaft includes a threaded connector at said other end, said threaded connector being in mechanical communication with said loaded end by way of said threaded nut.

4. The retention assembly of claim 3, wherein said threaded nut engages a shoulder of said loaded end of said shank.

5. The retention assembly of claim 1, wherein said inserted end of said shaft includes a tapered surface.

6. The retention assembly of claim 1, wherein said inserted end of said shaft includes a first diameter and a second diameter larger than said first diameter.

7. The retention assembly of claim 1, wherein said shaft, said carbide bolster, and said shank are coaxial.

8. The retention assembly of claim 1, wherein said inserted end of said shaft comprises at least one groove formed in a surface of said inserted end of said shaft.

9. The retention assembly of claim 1, wherein said retention assembly is incorporated into a tool selected from the group consisting of picks, drill bits, hammer mills, shear bits, and cone crushers.

10. The retention assembly of claim 1, wherein said inserted end of said shaft comprises a shaft geometry adapted to interlock with said cast material.

11. The retention assembly of claim 1, wherein an inner surface of said cavity of the carbide bolster comprises a cavity geometry adapted to interlock with said cast material.

12. The retention assembly of claim 1, wherein said cavity geometry comprises a tapered cavity surface that narrows towards an opening of the cavity formed in the base end.

13. The retention assembly of claim 12, wherein a diameter of the opening of said cavity formed in said base end is smaller than a diameter of said inserted end of said shaft.

14. The retention assembly of claim 1, wherein said carbide bolster further comprises a first segment and a second segment, wherein a portion of said cavity is formed in said first segment and another portion of said cavity is formed in said second segment.

15. The retention assembly of claim 1, wherein said inserted end of said shaft is in contact with said cavity of said carbide bolster.

16. The retention assembly of claim 1, further comprising a tip of carbide and diamond, said tip being brazed to said carbide bolster.

17. The retention assembly of claim 1, wherein the said retention assembly is incorporated into an item selected from the group consisting of a driving mechanism, a drum, a chain, and a rotor.

18. The retention assembly of claim 1, wherein inserted end of said shaft includes a tapered end, said cast material surrounding the entire tapered end of said shaft.

19. The retention assembly of claim 1, wherein said cast material and said carbide bolster are not significantly bonded to one another.

20. The retention assembly of claim 1, wherein said casting material and said first end do not have a strong bond.

21. A retention assembly for retaining a bolster to a shank, comprising: a bolster having a base end, the base end including a cavity formed therein;a shank including a first shank end, a second shank end, and a bore extending from said first shank end to said second shank end, said first shank end being adjacent to said bolster;a shaft disposed within said bore, said shaft including a first shaft end disposed within said cavity and a second shaft end in mechanical communication with said second shank end; anda cast material disposed within said cavity, said cast material retaining said first shaft end within said cavity.