The United States Air Force has decided to inspect the entire KC-46A Pegasus aerial refuelling fleet, produced by Boeing, after cracks were discovered in two of the four new aircraft set to be delivered to the US Military Delivery Centre. Due to the identified structural issues, KC-46 deliveries to both the US and Japan have been suspended.
Boeing Launches Comprehensive Inspection
Boeing announced that if any cracks are detected during the detailed inspections, the aircraft will be placed in a repair programme and will not be cleared for flight until repairs are completed. The identified cracks were reported to be in primary or secondary aviation structures, not on flight surfaces or hinges. In a statement, Boeing said, “We are working closely with the customer to assess a potential issue with the KC-46A aircraft and to minimise any potential impact on the fleet.”
Persistent Issues with KC-46A Pegasus
The KC-46A Pegasus programme has been plagued with technical issues even before its initial deliveries, which only began in 2019 — years behind schedule. Furthermore, the Fiscal Year 2024 Defence Operational Test and Evaluation (DOTE) Report revealed that the KC-46A’s operational availability rates were significantly below target levels. According to the report, readiness rates were 24% lower than expected due to frequent failures of the refuelling boom.
Boeing is working on hardware and software updates to resolve the issue of hard contacts during refuelling. Additionally, the Remote Vision System (RVS), which operators use to control fuel transfer, is undergoing a complete redesign. The current RVS system poses a safety risk as it causes physical discomfort for operators.
Mounting Costs and Delivery Delays
The KC-46A programme continues to incur massive costs for Boeing. In January 2024, the company reported an $800 million loss due to high production expenses. Under a fixed-price contract, Boeing has already lost billions of dollars on the programme.
In March 2024, a component failure in the refuelling boom caused a two-month delivery delay. The ongoing issues in the KC-46A programme, designed to replace the ageing KC-135 tanker fleet, are creating a significant gap in the US’s aerial refuelling capability.
What Lies Ahead?
Boeing’s ongoing technical struggles are directly affecting the US Air Force’s ability to conduct extended air operations. Experts predict that the KC-46A may take many more years to reach its intended operational capacity, potentially leaving a critical vulnerability in America’s air power.
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