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We have fixed the issue by fixing a script that was creating and mailing the pdf. It was doing some funky encoding that for some reason Outlook didn't like... not Outlook in general but only a couple specific users Outlook(which is still confusing to why it was happening and only to a couple...

My antivirus is Microsoft Security Essentials. You can not open the pdf by saving it to the desktop.

I am experiencing almost the same problem and it is driving me nuts. PDFs come up corrupt when trying to open them in Outlook 2010. If you open the same exact email through the web portal then it opens fine. On a different computer in Outlook 2010 the file will open fine. So this corruption...