FAA Aviation Mechanic Airframe (AMA)Airframe StructuresHard
A technician finds crushed honeycomb core cells beneath the skin of a composite sandwich panel during a repair. Before bonding a repair patch over the damaged area, what must the technician do to the crushed core?
- ALeave the crushed core as is since the patch will bridge the gap
- BFill the crushed core area with a potting compound to restore support before patching
- CRemove all core material from the panel and bond skins directly together
- DDrill relief holes through the crushed core to release trapped moisture
Show answer & explanationAnswer & explanation
Correct answer: B. Fill the crushed core area with a potting compound to restore support before patching
Crushed honeycomb core no longer provides adequate support for the skin. Per standard composite repair practice, the damaged core area must be filled with an approved potting compound to restore load-bearing support and provide a solid base before a repair patch is bonded over it; simply patching over an unsupported area can lead to skin flexing and repair failure.
Why the other options are wrong
- A. Leaving crushed core unsupported will cause the patch to flex and eventually fail.
- C. Removing all core material and bonding skins directly changes the panel's design and is not an approved standard repair.
- D. Drilling relief holes addresses trapped moisture in some repairs but does not restore structural support for crushed core.
Honeycomb Core Potting Repair
A repair technique where damaged or crushed honeycomb core is filled with a structural potting compound to restore support before bonding a skin patch.
- Crushed core loses its load-bearing capability
- Potting compound restores a solid, supportive base
- Common in sandwich panel repairs on flight control surfaces and fairings
Memory trick: 'Pot the Crush Before You Patch' — support first, cover second.