Narrative:

Nose cowl came into shop because of acoustic panel damage. Due to cowl history; an inspection and repair form was developed to encompass problem areas on the cowl. After inspection was complete; air carrier chose to disregard certain items because the repair time would take too long. 1) corrosion found in cowl mount holes. Management signed off write-up even though corrosion existed. Maintenance insisted on removing corrosion per the maintenance manual. 1 hole was so badly corroded it went from .375 to .500 before corrosion was removed. Even after holes were repaired; the alodine and prime step was still not completed to prevent future corrosion in a known corrosion area. 2) the fan case abutment groove on the aft edge of the cowl (entire circumference) ahd 50% of its flame spray missing and wear into the 'V' groove. After wear was blended and ready for flame spray; the decision was made to not flame spray; but to apply moly coat anti-abrasion. Then made the signoff using an unrelated engineering authority/authorized. This will result in premature failure of abutment face. Moly coat requires heat to cure. No heat was used -- moly is basically ineffective. Problem brought to management -- no results. Problem brought to management completing work -- no results. Problem brought to union standards committee -- no results. Problem being brought to FAA.

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Original NASA ASRS Text

Title: A B757-200 ENG INLET COWLING SHOP TECHNICIAN ALLEGES IMPROPER REPAIR PROCS BEING PRACTICED WITH UNRELATED ENGINEERING AUTHS.

Narrative: NOSE COWL CAME INTO SHOP BECAUSE OF ACOUSTIC PANEL DAMAGE. DUE TO COWL HISTORY; AN INSPECTION AND REPAIR FORM WAS DEVELOPED TO ENCOMPASS PROB AREAS ON THE COWL. AFTER INSPECTION WAS COMPLETE; ACR CHOSE TO DISREGARD CERTAIN ITEMS BECAUSE THE REPAIR TIME WOULD TAKE TOO LONG. 1) CORROSION FOUND IN COWL MOUNT HOLES. MGMNT SIGNED OFF WRITE-UP EVEN THOUGH CORROSION EXISTED. MAINT INSISTED ON REMOVING CORROSION PER THE MAINT MANUAL. 1 HOLE WAS SO BADLY CORRODED IT WENT FROM .375 TO .500 BEFORE CORROSION WAS REMOVED. EVEN AFTER HOLES WERE REPAIRED; THE ALODINE AND PRIME STEP WAS STILL NOT COMPLETED TO PREVENT FUTURE CORROSION IN A KNOWN CORROSION AREA. 2) THE FAN CASE ABUTMENT GROOVE ON THE AFT EDGE OF THE COWL (ENTIRE CIRCUMFERENCE) AHD 50% OF ITS FLAME SPRAY MISSING AND WEAR INTO THE 'V' GROOVE. AFTER WEAR WAS BLENDED AND READY FOR FLAME SPRAY; THE DECISION WAS MADE TO NOT FLAME SPRAY; BUT TO APPLY MOLY COAT ANTI-ABRASION. THEN MADE THE SIGNOFF USING AN UNRELATED ENGINEERING AUTH. THIS WILL RESULT IN PREMATURE FAILURE OF ABUTMENT FACE. MOLY COAT REQUIRES HEAT TO CURE. NO HEAT WAS USED -- MOLY IS BASICALLY INEFFECTIVE. PROB BROUGHT TO MGMNT -- NO RESULTS. PROB BROUGHT TO MGMNT COMPLETING WORK -- NO RESULTS. PROB BROUGHT TO UNION STANDARDS COMMITTEE -- NO RESULTS. PROB BEING BROUGHT TO FAA.

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.