Narrative:

Engine #1 and #2 inbd pylon panels delam/outer aluminum layer eroded away. Honeycomb layers were exposed. These panels were deferred to perform repair at a later opportunity. Discrepancies on both panels beyond structural repair manual limits. The structural integrity of both panels is compromised. Aircraft X arrived in ZZZ may/fri/05. Maintenance found #1 and #2 engine pylon panels delaminated and a hole. Allowable damage beyond limits per structural repair manual. Maintenance threatened by management to disregard. Maintenance found carry forward item limits outside of approved documents. Management handled paperwork and maintenance is trying to work quality assurance to remedy the problem. Condition is clearly out of limits. Callback conversation with reporter revealed the following information: the reporter stated that with the outer aluminum covering stripped off the kevlar honeycomb; you could observe vertical grey streaks in the composite panel where it bubbled or bulged outward and the air stream polished the bulged surface. The delamination reportedly was beyond the structural limits and could not have been legally deferred. After advising the supervisor of the condition of the panels and the structural repair limits; the reporter was threatened with firing. The panels were deferred by the supervisor to be replaced or repaired.

Google
 

Original NASA ASRS Text

Title: A B767-300 WAS FOUND TO HAVE LEFT AND RIGHT ENG INBOARD NACELLE STRUT COMPOSITE PANELS DELAMINATED AND OUTER ALUMINUM LAYER ERODED WITH HONEYCOMB EXPOSED BEYOND STRUCTURAL REPAIR MANUAL LIMITS.

Narrative: ENG #1 AND #2 INBD PYLON PANELS DELAM/OUTER ALUMINUM LAYER ERODED AWAY. HONEYCOMB LAYERS WERE EXPOSED. THESE PANELS WERE DEFERRED TO PERFORM REPAIR AT A LATER OPPORTUNITY. DISCREPANCIES ON BOTH PANELS BEYOND STRUCTURAL REPAIR MANUAL LIMITS. THE STRUCTURAL INTEGRITY OF BOTH PANELS IS COMPROMISED. ACFT X ARRIVED IN ZZZ MAY/FRI/05. MAINT FOUND #1 AND #2 ENG PYLON PANELS DELAMINATED AND A HOLE. ALLOWABLE DAMAGE BEYOND LIMITS PER STRUCTURAL REPAIR MANUAL. MAINT THREATENED BY MGMNT TO DISREGARD. MAINT FOUND CARRY FORWARD ITEM LIMITS OUTSIDE OF APPROVED DOCUMENTS. MGMNT HANDLED PAPERWORK AND MAINT IS TRYING TO WORK QUALITY ASSURANCE TO REMEDY THE PROB. CONDITION IS CLEARLY OUT OF LIMITS. CALLBACK CONVERSATION WITH RPTR REVEALED THE FOLLOWING INFO: THE RPTR STATED THAT WITH THE OUTER ALUMINUM COVERING STRIPPED OFF THE KEVLAR HONEYCOMB; YOU COULD OBSERVE VERTICAL GREY STREAKS IN THE COMPOSITE PANEL WHERE IT BUBBLED OR BULGED OUTWARD AND THE AIR STREAM POLISHED THE BULGED SURFACE. THE DELAMINATION REPORTEDLY WAS BEYOND THE STRUCTURAL LIMITS AND COULD NOT HAVE BEEN LEGALLY DEFERRED. AFTER ADVISING THE SUPVR OF THE CONDITION OF THE PANELS AND THE STRUCTURAL REPAIR LIMITS; THE RPTR WAS THREATENED WITH FIRING. THE PANELS WERE DEFERRED BY THE SUPVR TO BE REPLACED OR REPAIRED.

Data retrieved from NASA's ASRS site as of January 2009 and automatically converted to unabbreviated mixed upper/lowercase text. This report is for informational purposes with no guarantee of accuracy. See NASA's ASRS site for official report.