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Air Force says KC‑46 deliveries to resume after wing‑support cracks; long‑term tanker recapitalization still unsettled
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Summary
Acting Air Force acquisition chief and Air Staff official told the House subcommittee all 89 KC‑46s were inspected after wing‑support cracks were found, with repairs on all but three and resumption of Boeing deliveries expected. Lawmakers pressed officials on Remote Vision System delays and broader plans to replace aging KC‑135 tankers.
Acting Assistant Secretary of the Air Force for Acquisition, Technology and Logistics Darlene Castello told the House Armed Services Subcommittee that the KC‑46 tanker program has completed inspections of the fleet after cracks were found in the wing‑support structure and that Boeing deliveries will resume.
“We inspected all 89 KC‑46 aircraft,” Castello said. “Cracks were identified on 21 total aircraft, and all but 3 have since been repaired. The program office, Boeing, and Air Mobility Command have identified the root cause, and we have begun the process to resume deliveries from Boeing. And the first delivery is expected to resume next week.”
The statement came as members pressed Air Force witnesses about two linked issues: near‑term KC‑46 structural defects and delays to the Remote Vision System (RVS), the camera‑based boom operator system. Ranking Member Joe Courtney asked whether recent reporting of another year‑long delay to RVS completion was accurate; Castello said Boeing provided an estimate that pushed some certification work toward the end of fiscal 2027 but that the Air Force is working to “bring that to the left.” She added that a “fully demonstrated RVS system” exists in the lab and is being installed on the first aircraft, with flight testing planned later this year.
Lieutenant General Dave Taber, deputy chief of staff for plans and programs, and Castello both stressed that recapitalization of the aging KC‑135 fleet remains a priority. Castello said the service “is absolutely committed to recapitalizing that fleet” and will “take advantage” of KC‑46 buys in the near term while evaluating affordable options for the time between KC‑46 completion and a future tanker solution. Taber noted that statutory planning baselines set a minimum tanker force size at 466 aircraft and called that number a “hard line” they intend to maintain while acknowledging cases can be made for different force levels.
Lawmakers pushed for clearer timelines as they weigh sustainment and modernization tradeoffs. Castello said the Air Force is still determining an acquisition strategy for a next‑generation tanker but is prioritizing KC‑46 production and working with Boeing to resolve deficiencies.
The exchange highlighted two practical gaps: immediate aircraft availability affected by structural repairs and the downstream effects on training and certification tied to RVS. Committee members also asked about operational limitations for KC‑46s flying without full RVS capability; Castello and Taber described the current aircraft as “capable” but said they will be more able when RVS is fielded.
The Air Force did not announce new force‑structure decisions or a timeline to begin a formal next‑generation tanker program during the hearing. Members asked for continued updates as the Air Force reconciles short‑term fixes with longer‑term recapitalization planning.
