The US Air Force has made the decision to temporarily halt the acceptance of new KC-46 aerial refueling aircraft from Boeing after the discovery of cracks in two out of four planes that were deemed ready for delivery. These cracks were identified in the outboard fixed-trailing-edge support structure of the aircraft, according to an announcement from the KC-46 program office.
Although the damage is not considered to pose an immediate safety risk, officials underscored the importance of addressing the issue promptly to avoid any potential reductions in flight durations and limitations on the aircraft’s range. A spokesperson for the program indicated that Boeing, in coordination with the program office and Air Mobility Command, is engaged in efforts to swiftly ascertain the root cause of the cracks and to formulate both immediate and long-term solutions.
In light of this latest setback, the Air Force plans to conduct inspections of its existing fleet of 89 KC-46A Pegasus tankers currently in service. This follows a pattern of technical challenges that have plagued the KC-46 program over the years.
Initially lauded as an ideal solution for US tanker aircraft recapitalization, the KC-46 provides a substantial fuel capacity of 212,000 pounds (approximately 96,161 kilograms), designed to enhance the operational range of various US military aircraft. Furthermore, the aircraft can be reconfigured for transport missions, carrying up to 65,000 pounds (about 29,484 kilograms) or accommodating 58 fully-equipped soldiers.
Despite the potential benefits, the KC-46 program has faced significant hurdles. A 2022 report by the US Government Accountability Office highlighted seven “category one” deficiencies associated with the tanker. These issues were considered serious enough to present risks of death, severe injury, or critical occupational illnesses, leading the Air Force to suspend deliveries in February 2023 to allow Boeing time to rectify quality concerns.
Nonetheless, the Air Force remains hopeful about the KC-46’s future. This optimism is reflected in their decision to identify seven potential bases for the advanced aerial refueling aircraft, indicating a continued commitment to the program despite the current challenges it faces.
