Wear resistant tool bit

1. A tool bit for driving a fastener, the tool bit comprising:

a shank including

a tool coupling portion configured to be coupled to a tool, the tool coupling portion having a hexagonal cross-sectional shape, and

a head portion configured to engage the fastener,

wherein the head portion is composed of powdered metal (PM) steel having carbide particles distributed uniformly throughout the head portion, and wherein the tool coupling portion is composed of a different material than the head portion.

2. The tool bit of claim 1 , wherein the PM steel has a carbide particle concentration of at least 6% by volume.

3. The tool bit of claim 2 , wherein the PM steel has a carbide particle concentration between about 10% to about 15% by volume.

4. The tool bit of claim 1 , wherein each of the carbide particles has a similar shape and a similar size.

5. The tool bit of claim 4 , wherein each of the carbide particles is round, and wherein an average area of each carbide particle is about 1.585 microns 2 .

6. The tool bit of claim 1 , wherein the head portion of the shank includes a Phillips head #2 geometry.

7. The tool bit of claim 1 , wherein the head portion of the shank includes a plurality of flutes in which each flute has a radius of curvature between about 0.8 mm and about 1.0 mm.

8. The tool bit of claim 1 , wherein the head portion has a hardness between about 61 and about 63 HRC.

9. The tool bit of claim 1 , further comprising a nickel coating on the head portion of the shank.

10. The tool bit of claim 1 , wherein the shank further includes an intermediate portion extending between the tool coupling portion and the head portion, wherein the intermediate portion has a cylindrical shape.

11. The tool bit of claim 1 , wherein the head portion, the intermediate portion, and the tool coupling portion are integral.

12. The tool bit of claim 11 , wherein a diameter of the intermediate portion is less than an outer dimension of the hexagonal cross-sectional shape of the tool coupling portion.

13. A method of manufacturing a tool bit for driving a fastener, the method comprising the steps of:

providing powdered metal (PM) steel;

atomizing the PM steel into micro ingots;

injecting the atomized PM steel micro ingots into a mold; and

sintering the atomized PM steel micro ingots, while in the mold, into the tool bit such that carbide particles are uniformly distributed throughout the tool bit, the tool bit including a tool coupling portion having a hexagonal cross-sectional shape configured to be coupled to a tool and a head portion configured to engage the fastener.

14. The method of claim 13 , wherein sintering the atomized PM steel micro ingots includes hot isostatic pressing the atomized PM steel micro ingots to form the tool bit.

15. The method of claim 13 , wherein sintering the atomized PM steel micro ingots includes forming the tool bit with carbide particles each having a similar shape and a similar size.

16. The method of claim 13 , wherein atomizing the PM steel micro ingots includes atomizing the PM steel micro ingots with Argon gas.

17. A method of manufacturing a tool bit for driving a fastener, the method comprising the steps of:

providing a round stock of powdered metal (PM) steel having carbide particles uniformly distributed throughout the round stock;

providing a hex stock of non-PM steel;

joining the round stock of PM steel to the hex stock of non-PM steel;

milling the hex stock of non-PM steel into a tool coupling portion of the tool bit having a hexagonal cross-sectional shape configured to be coupled to a tool; and

milling the round stock of PM steel into a head portion of the tool bit configured to engage the fastener.

18. The method of claim 17 , wherein providing the round stock includes providing the round stock of PM steel with carbide particles each having a similar shape and a similar size.

19. The method of claim 17 , wherein providing the hex stock includes providing the hex stock of 6150 steel or D6A steel.

20. A method of manufacturing a tool bit for driving a fastener, the method comprising the steps of:

providing powdered metal (PM) steel;

sintering the PM steel to form a hex-shaped block having carbide particles uniformly distributed throughout the hex-shaped block; and

milling the hex-shaped block into the tool bit, the tool bit including a tool coupling portion having a hexagonal cross-sectional shape configured to be coupled to a tool and a head portion configured to engage the fastener.

21. The method of claim 20 , wherein sintering includes hot isostatic pressing the PM steel to form the hex-shaped block.

22. The method of claim 20 , wherein sintering the PM steel includes forming the hex-shaped block with carbide particles each having a similar shape and a similar size.

23. The method of claim 20 , further comprising atomizing micro ingots into the PM steel with Argon gas.