We've experienced the same issue using Exchange mail server in our office.
It occasionally occurs when we receive Illustrator files from customers. The customers sends the Illustrator file to the sales person (which comes over correctly as an .ai file) and when the sales person forwards the file to me from their Windows computer, I receive a .as file, which I cannot open. The solution for us has been for the sales person to download the Illustrator file to their computer first, reattach the file and then send it directly to me. That seems to fix the problem, although its a bit of an inconvenience. We have not figured out the exact cause, but the suspicion has been that its the Exchange mail server and/or the Mac/Windows compatibility using Apple Mail when attachments are forwarded. I'm not knowledgeable enough about operating systems to troubleshoot what causes this problem to happen.
@RedCrayonDesign - I was having the same .as file issue when I was running OS Mavericks and I am now running Sierra and still have the same issue.