When replacing a damaged honeycomb core with balsa wood, how should the plug be cut?

When replacing a damaged honeycomb core with balsa wood, it is crucial that the grain of the balsa wood plug is cut perpendicular to the skin. This orientation is significant because it allows the balsa wood to provide optimal strength and support against the loads that the skin will encounter during operations.

Balsa wood has a grain structure that gives it specific mechanical properties. When installed with the grain parallel to the skin, the material would not effectively bear the shear and compressive loads, leading to potential failure or deformation. Positioning the grain perpendicularly maximizes the load-bearing capability and enhances the overall structural integrity of the repair.

Orientation at a 45-degree angle or with no specific grain direction would not utilize the material's properties effectively. Conducting repairs in such a manner could risk the durability of the structure, especially in load-bearing applications typical of aviation environments. Therefore, ensuring the grain is perpendicular is fundamental for maintaining the strength of the repaired area.