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This research focuses on investigating the mechanical behavior of cracked aluminum panels repaired with bonded boron/epoxy composite patches. The effects of crack initiation and growth on the residual strength of the repaired panels are characterized. This research establishes a correlation between damage modes, residual strength and evolution of strain within as well as outside the patch. Monotonic tensile tests on specimens with a perfectly bonded patch were used to determine the base line strength. Likewise, fatigue tests on specimens with a perfectly bonded patch served to establish baseline fatigue life. In addition, several specimens with a perfectly bonded patch were subjected to different fractions of the expected fatigue life, introducing damage, which were quantified by NDE techniques.