The US Air Force is temporarily refusing to accept new KC-46 aerial refueling aircraft from Boeing after discovering cracks in two of four ready-for-delivery planes.
The cracks were found in the “outboard fixed-trailing-edge support structure” of the aircraft, according to an announcement issued by the service’s KC-46 program office.
While the damage does not pose a serious safety risk, a spokesperson explained that it must be repaired immediately to prevent reduced flight durations and limited range.
“Boeing, the program office, and Air Mobility Command are working to quickly identify the root cause and develop both a near and long-term way ahead,” the spokesperson noted.
The latest issue will prompt the US Air Force to inspect its fleet of 89 KC-46A Pegasus tankers already in service.
Persistent Technical Challenges
Boeing’s KC-46 aircraft was once hailed as the “logical choice” for US tanker aircraft recapitalization, offering a fuel capacity of 212,000 pounds (96,161 kilograms) to extend the range of other US military aircraft.
It can also be reconfigured as a transport plane, with a maximum cargo capacity of 65,000 pounds (29,484 kilograms) or 58 fully-equipped soldiers.
However, the KC-46 program has hit a rough patch.
In 2022, the US Government Accountability Office reported that the tanker aircraft had seven “category one” deficiencies — issues deemed serious enough to potentially cause death, severe injury, or serious occupational illnesses.
This prompted the US Air Force to halt deliveries in February 2023 to give Boeing time to address the quality concerns.
Despite the ongoing challenges, the service remains optimistic about the KC-46, demonstrating continued confidence by already selecting seven potential bases for the advanced aerial refueler.
