The KC-46A Pegasus is the next-generation aerial refueling tanker developed by Boeing to modernize the U.S. Air Force’s aging fleet of KC-135 Stratotankers.
“The KC-46A is the first phase in recapitalizing the U.S. Air Force's aging tanker fleet. With greater refueling, cargo and aeromedical evacuation capabilities compared to the KC-135, the KC-46A will provide aerial refueling support to Air Force, Navy, Marine Corps and partner-nation receivers,” explains the U.S. Air Force (USAF).
The aircraft has been in development since Feb. 24, 2011, and its initial flight occurred in Dec. 2014.
“Built to meet the requirements of the U.S. Air Force and allies for the full spectrum of missions, the combat-ready KC-46 Pegasus air refueling plane delivers proven multi-mission capabilities today, and evolves to meet the needs of tomorrow,” says maker Boeing.
The current contract, with options, provides Air Mobility Command with an inventory of 179 KC-46A tankers. The first KC-46A was delivered to McConnell Air Force Base, Kansas on Jan. 25, 2019.
Gen. Mike Minihan, commander of Air Mobility Command, approved the KC-46A Pegasus for worldwide deployments to meet combatant command taskings effective Sept. 14, 2022.
“We are ready to use this aircraft globally in any fight, without hesitation,” Minihan said. “We have rapidly operationalized this aircraft to support the joint force. We’re taking a hard look at our entire toolkit to make sure we extract maximum value to be ready for a high-end fight.”
Deliveries of the KC-46A were halted temporarily in March 2025 after discovery of cracks in the aileron hinges on two of the tankers ready for delivery.
The KC-46A Pegasus at full operational capability can refuel most fixed-wing, receiver-capable aircraft.
“The KC-46A is equipped with a refueling boom driven by a fly-by-wire control system and is capable of fuel offload rates required for large aircraft. Its hose and drogue system adds additional mission capability that is independently operable from the refueling boom system,” says the USAF.
The KC-46A can also accommodate a mixed load of passengers, aeromedical evacuation and cargo capabilities.
Other features of the KC-46A include:
“The KC-46A is also equipped with a number of self-protection, defensive and communication features making it more survivable in a contested environment,” says the USAF.
Boeing says that the KC-46A delivers life-cycle value backed by a robust supply chain that includes more than 650 American businesses and 37,000 American workers.
“Built as a combat-ready tanker from day one of production, the KC-46A has a longer lifespan and a reduction in the airframe corrosion that can occur in post-production modification. Furthermore, fleet commonality and interoperability leverages economy of scale for the U.S. Air Force and allies,” says Boeing. “The operating cost of four KC-46A tankers is the same as just three larger refuelers, so operators can have more booms in the air and bring more fuel to the fight.”
The aftermarket for the KC-46A Pegasus includes Source One Spares, a recipient of two USAF Aviation Equipment & Parts Support Contracts as part of the KC-46 Aerial Tanker Program.
“Ultimately, the in-production KC-46A has lower acquisition, operations and sustainment costs than any existing widebody aerial refueler and represents the best value over its total lifecycle,”concludes Boeing.
The Aviationist reported on March 7, 2025, that the USAF paused deliveries of the KC-46 and launched a fleet-wide inspection on the 89 aircraft currently in service after cracks were discovered in the outboard fixed-trailing-edge support structure of two planes set to be handed over to the military.
“To put it simply, the cracks are located on the aileron hinges, but they do not involve the flight surfaces. The Boeing 767, from which the KC-46 is derived, was already known for the risk of developing cracks on the aileron hinges over time, however the discovery of the cracks on a newly built aircraft required immediate action,” reported the publication.
The USAF told The War Zone publication that Boeing “is taking measures to temporarily halt deliveries until we fully understand the root cause and implement an effective corrective action plan.”
Later the USAF also said: “The damage does not pose a safety-of-flight concern; however, identified cracks must be repaired before returning an aircraft to service. 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.”
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