What must be done to the damaged area in a bonded honeycomb structure before repairs begin?

In a bonded honeycomb structure, it is crucial to remove the damaged area completely before initiating repairs. This process involves cutting out the damaged section to ensure that the repair is performed on structurally sound material. Honeycomb structures rely on the integrity of both the inner core and the outer skins to maintain their strength and performance characteristics. If any damaged material is left in place, it could compromise the repair's effectiveness, leading to potential failures in the structure under operational loads.

By fully removing the damaged area, it allows for a proper fit and bond for the repair patch, ensuring that the new material can effectively carry loads and maintain the overall integrity of the structure. This step is essential for restoring the strength and performance of the honeycomb component and ensuring safety in its application.