Abstract: A composite architectural frame section with subcomponents that meet functional, strength and thermal isolation requirements is assembled using knurling and crimping operations as joining procedures. When properly designed the knurling and subcomponent geometries with proper crimping operations result in an optimal shearing strength between critical subcomponents, thus maximizing the structural performance aspect of the frame section. Various embodiments of this design address requirements for subcomponent features such as: hammer and anvil tips, orientation of knurled and crimped surfaces, design of the knurling wheel components, and the introduction of alternate surface topographies to additional regions of these contacting frame subcomponents. These embodiments serve to maximize the portion of available interface contact surfaces and their friction that can bear shearing forces and, thus, add to the overall shear strength of the frame section.

Abstract: Porosity of aluminum ingot can be evaluated using focused beam ultrasonic testing and/or florescent dye penetrant testing. The aluminum ingot can be machine cut to form an aluminum ingot slice prior to testing. The machine cut can be performed using a polycrystalline cutting material in a “fly cutter” configuration. The polycrystalline cutting material can comprise a diamond material. The insert can cut an aluminum ingot slice to a surface roughness finish in the range of about 7-9 micro inches.