So on Saturday I bought a brand new 1/2" shank Whiteside rabbetting bit set. It didn't disappoint, and the first 8 operations went flawlessly. It easily handled a very heavy cut using a medium duty hand-held router. Of course, the cut quality was great as well. On the 9th operation I had to make a climb cut, and suddenly a chunk of wood broke free and my router became a wood chipper. The router hardly kicked, and suddenly the wood was starting to burn. It took me a few minutes before I actually looked at the bit. To my horror a full width chunk of carbide was completely gone! My cut had been controlled, not too heavy as it was a climb cut, and there was no foreign object in the wood. After further examination I decided it had to be a defect in the carbide, because half of the cutter blade looked like broken carbide, and the other half was dark, semi-shiny and smooth (which didn't look like normal broken carbide).
Any one else have this happen before? With Whiteside?
Luckily I didn't get hit by the flying piece, and the workpiece was fully intact as well. I returned the bit for a new one, but my next pass I made while wearing a face shield.