Lawmakers Restrict KC-46 Purchases, Extend KC-135 Lifespan

The US Congress has imposed limitations on the procurement of the Boeing KC-46 Pegasus, the latest aerial tanker for the US Air Force (USAF). Lawmakers have decided to reduce the planned acquisition from over 250 aircraft to a maximum of 183 due to ongoing engineering and performance issues that remain unresolved. In light of these deficiencies, Congress has also opted to extend the retirement timeline for the aging KC-135 Stratotanker until the KC-46 can demonstrate its operational reliability.

Concerns Over Performance and Future Plans

In July, the USAF made a strategic decision to forego a competition for new tanker models, instead focusing on purchasing an additional 75 KC-46s to bolster its fleet. According to a report by Air and Space Forces Magazine, this move aims to improve the existing KC-135 fleet while preparing for the eventual retirement of older tankers, including the KC-10 Extender.

The current limitation on KC-46 acquisitions will remain in place until Congress receives a comprehensive corrective action plan addressing the performance deficiencies associated with the aircraft. Jack Flynt, a veteran of the Air Force who transitioned from operating the KC-135 to the KC-46, emphasized the aircraft’s potential in enhancing air refueling capabilities. He remarked, “We’re making leaps and bounds with the KC-46A. Together, we are strengthening the KC-46 program to promote continued mission readiness and unmatched global air refueling operations.”

Expanding Overall Tanker Capacity

While Congress is slowing the pace of KC-46 acquisitions, lawmakers are simultaneously pushing to expand the overall tanker fleet capacity. The draft 2026 National Defense Authorization Act (NDAA) proposes increasing the statutorily required USAF tanker fleet from 466 aircraft to 504 by 2027. This change aims to ensure that the Air Force maintains a robust refueling capability in the face of evolving operational demands.

Restrictions on retiring older airframes will also be enforced. If the USAF does not meet the required minimum number of KC-135s and KC-46s by the target date, Congress mandates that any decommissioned KC-10s must remain in a flyable condition. Additionally, each KC-10’s in-flight refueling boom must be retained, and these aircraft cannot be repurposed for spare parts.

The KC-46 offers advanced features that enhance its operational capabilities. It includes a multirole cargo and passenger capacity, accommodating up to 54 patients in aeromedical evacuation configurations. The aircraft benefits from modern technology such as a fly-by-wire boom, wing aerial-refueling pods, and a state-of-the-art Remote Vision System for enhanced situational awareness.

The KC-46 also integrates advanced electronic systems for countermeasures and communication, including the ALR-69A(V) radar warning system and Secure Link-16 capabilities. Its improved fuel efficiency—20-25% better than the KC-135—coupled with on-condition monitoring, significantly reduces maintenance times, enhancing overall operational readiness.

As the USAF navigates these challenges, the emphasis remains on ensuring the air refueling capabilities that are vital for supporting diverse military operations. The balancing act of managing aging aircraft while integrating new technology continues to shape the future of America’s aerial refueling fleet.