What is a common consequence of re-drilling already drilled holes?

Re-drilling already drilled holes can lead to potential structural weakness in the material. When a hole is drilled, the surrounding material is altered; the integrity of the material can be compromised, especially if the re-drilling leads to oversized holes or removes additional material from the area. This can affect load distribution and could make the part more susceptible to failure under stress or strain.

Additionally, if the new hole does not align properly with the original hole, it can cause misalignments in assembly, which can further degrade structural integrity. In aerospace applications, maintaining the strength and reliability of components is critical, as even small weaknesses can have significant consequences during operation. Therefore, the act of re-drilling often necessitates careful evaluation and possibly the use of techniques to reinforce the area, highlighting the serious implications of this practice.