When repairing puncture-type damage to a laminated honeycomb panel, how should the edges of the doubler be tapered?

When repairing puncture-type damage to a laminated honeycomb panel, the edges of the doubler should be tapered at 100 times the thickness of the metal. This specific tapering is critical because it distributes the load more evenly across the repair area, reducing stress concentration at the edges. A gradual taper helps to minimize any potential for crack initiation, which can occur at sharp edges.

Tapering at this ratio ensures that the transition from the repaired section to the existing structure is smooth, thereby enhancing the integrity and durability of the repair. It is particularly vital in aerospace applications where structural integrity is crucial for safety and performance.

In contrast, smaller taper ratios could lead to insufficient load distribution, resulting in a more abrupt change in thickness that can create stress points, making the repair less effective. Therefore, tapering at a ratio of 100 times the thickness of the metal is the established practice to achieve optimal repair quality.