"Shortly before sunrise on Jan. 23, 2009, passengers on US Airways Flight 518, who were flying from Omaha to Phoenix, were startled by a terrifying shriek.
The pressure seal around the main cabin door was failing, and that shriek was the sound of air leaking through. The plane diverted to Denver. Everybody was safe.
But that and other recent malfunctions affecting US Airways planes, which NPR is reporting for the first time, raise questions about a controversial and growing practice at most U.S. airlines: The industry is sending 1 of every 5 planes to developing countries, from Central America to Asia, when the planes need to be overhauled and repaired.
In the weeks before the door seal started to fail, US Airways had sent that Boeing 737 to be overhauled at Aeroman, a repair company in El Salvador. And mechanics installed a key part on the door — a "snubber" — backward.
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"Since the airline crisis hit seven years ago, the statistics have flip-flopped: The industry is now sending most of its planes to be overhauled and fixed at private repair shops both in the U.S. and overseas. And roughly 20 percent of planes are going to facilities in developing countries, according to industry surveys.
Industry analysts say there are roughly 700 FAA-approved repair companies in other countries — including repair shops in Argentina, Costa Rica, Ethiopia, Kenya, China and Indonesia. The Aeroman company in El Salvador is becoming one of the more popular, drawing business from US Airways, JetBlue, Frontier, Southwest and other U.S. carriers. "
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