FAA Sheet Metal Structures Practice Test 2025 – 400 Free Practice Questions to Pass the Exam

When designing a patch for a small hole in a metal stressed skin, one of the most critical considerations is the shear strength of the riveted joint. This is because the joint's ability to resist failure under shear loads is vital to maintaining the structural integrity of the aircraft.

The design must ensure that the patch, along with the rivets or fasteners used to secure it, can effectively handle the operational loads that the skin will encounter during flight. If the shear strength of the joint is insufficient, there is a risk of failure, which could compromise the safety and performance of the aircraft. Therefore, using materials that will provide adequate shear strength at the joint, and ensuring that the rivet spacing and size are appropriate for the load conditions, are essential elements in the patch design process.

Other considerations, like the cost of materials, creep resistance, or aesthetics, while they may have some relevance, do not carry the same weight as ensuring the mechanical reliability and safety of the repair in the context of aviation safety.