Quoted:
On sword-length blades, fullers serve to lighten the blade while retaining stiffness. Like a fluted rifle barrel, you end up with a blade that is stiffer than an un-fullered blade of the same weight.....
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Removing metal from a piece can not make it stronger except maybe when very heavy pieces are concerned, as in I-beams.
Please note he says "of the same weight".
Removing metal from a blade or a rifle barrel can [b]not[/b] make that same piece any stiffer.
However changing the design to include the fluting or fuller can allow more metal to be concentrated in the areas critical to strength.
This allows you to make a stronger, fluted, piece with the same weight as the ordinary piece (one that has metal in the areas that contribute least to strength).
Maybe an engineer can explain it better, but I think in the case of an I-beam, it's the same issue: placing the metal in the cross-section in such a way that puts it where it contributes most to strength. In a large, long piece, you would have the added consideration that metals in any areas not optimal to the ideal design actually become more or less dead weight, weighing the span down while not adding much to it's ability to resist design stresses.
[red]PRK