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How about something like those, uh, dunno the technical weapon term, polearm whose blade side extend past the hilt/socket/whatever, like a bearded axe, but along the length of that beard, there are truss/connector to the pole?
The point of weakness in the sword is when the tang is thicker than the blade, which stops shock at the guard, where most swords snap. With most polearms, you have an aspect where the blade is no longer than a knife, which will then require more force to snap. Bearding doesn't introduce different thicknesses so shock is an issue there. You get other problems, like locking, I'd imagine.
Basically, the problem of the swordstaff is also its greatest strength, greater cutting reach also means a greater length to test the extent of metallurgy technology and skill. Of course other polearms have the problem that they snap more often in general because, well, wood. Basically, swordstaff amplifies a weakness of the sword, while removing its capability to be a sidearm.
+randomly reads a bit into tang and stuff+
So, full tang is probably better? Something like having a metal core staff or full metal staff, either with blade welded on or blade actually being part of it from the shaping?
Thanks for the info though, pretty interesting read.
Good luck trying to fit that in wood, which changes due to moisture, or as a full bar, keeping it light enough to wield. With a metal staff, the problem comes to flexibility and maneuverability. Especially in European metallurgy, you see too much bending.