What is the major design consideration when repairing a small hole on a metal stressed skin?

When addressing the major design consideration for repairing a small hole on a metal stressed skin, the shear strength of the riveted joint is paramount. Stressed skin structures rely on multiple layers of materials, including the skin and the rivets that secure it. The repair process must ensure that the integrity of the joint is maintained or enhanced, especially in an aircraft or other load-bearing structures, where the shear forces acting on the riveted joints are critical for the overall performance and safety.

In this context, while the thickness of the skin is important for the strength of the repair, and the weight of the patch is a consideration to prevent undue stress on the structure, they do not override the necessity for maintaining adequate shear strength in the joint. The cost of materials can also be a factor, but it typically does not take precedence over the structural integrity that the shear strength provides. Ensuring that the patch strengthens the joint and adheres to the required shear strength standards is vital for the long-term reliability of the repair.