The KC-46 Pegasus program achieved an important milestone July 6, 2018, at Boeing Field, Seattle, with completion of the final flight tests required for first aircraft delivery planned in late October.

The integrated Air Force and Boeing test team completed all required test points for the Remote Vision System and for receiver certifications of the F-16 Fighting Falcon and C-17 Globemaster III. These two receivers, coupled with testing completed in June of KC-135 Stratotanker refueling the KC-46 Pegasus as a receiver, are the minimum required for delivery.

«With this milestone complete, the test program has demonstrated a level of maturity that positions Boeing to deliver, and the Air Force to accept, an aircraft by the end of October 2018», said Doctor Will Roper, the Air Force service acquisition executive.

The KC-46 Pegasus test program is now transitioning to follow-on receiver aircraft testing and certifications required for operational testing starting in 2019.

On June 4, 2018, Chief of Staff of the Air Force General David L. Goldfein met with the men and women testing the KC-46 Pegasus at Boeing Field to witness their hard work firsthand. While flying on a scheduled KC-46 Pegasus test mission, Goldfein flew the aircraft and its boom in between test points and observed C-17 Globemaster III receiver aircraft certification testing.

«It was a pleasure to fly the KC-46 Pegasus, an aircraft that will enhance our lethality and global warfighting capabilities», Goldfein said. After the recent test point completion, he added, «I am encouraged by the team’s progress in putting another significant milestone behind us. The collective Air Force, Boeing, Federal Aviation Administration, and Defense Contract Management Agency team is laser-focused on the remainder of activities needed to certify and accept this much-needed tanker in late October. I am excited for our Air Force as we move closer to having this aircraft in the hands of our warfighters who will unleash its demonstrated capabilities in support of the Joint fight».

General Characteristics

A Boeing-led team, including U.S. Air Force and Naval Air Systems Command representatives, recently completed KC-46 Pegasus tanker electromagnetic testing.

This testing evaluates the aircraft’s ability to safely operate through electromagnetic fields produced by radars, radio towers and other systems under mission conditions.

«The KC-46 tanker is protected by various hardening and shielding technologies designed into the aircraft to negate any effects on the aircraft», said Mike Gibbons, Boeing KC-46 vice president and program manager. «This successful effort retires one of the key risks on the program».

Testing was conducted on the Naval Air Station Patuxent River, Maryland, Electromagnetic Pulse (EMP) and Naval Electromagnetic Radiation Facility pads and also in the Benefield Anechoic Facility at Edwards Air Force Base, California.

During tests on the EMP pad at Patuxent River, the program’s second low-rate initial production KC-46 Pegasus received pulses from a large coil/transformer situated above the aircraft. The outdoor simulation was designed to test and evaluate the KC-46’s EMP protection while in flight.

The KC-46A Pegasus is a multirole tanker that is designed to refuel all allied and coalition military aircraft compatible with international aerial refueling procedures and can carry passengers, cargo and patients.

Boeing is assembling KC-46 Pegasus aircraft at its Everett, Washington, facility.

General Characteristics

Boeing now has six aircraft in its KC-46 Pegasus tanker test program, expanding its ability to complete ground and flight-test activities as it progresses toward first deliveries to the U.S. Air Force.

The newest KC-46 Pegasus aerial refueling aircraft, the second low-rate initial production plane, completed its first flight April 29. Its test activities will help ensure the KC-46 Pegasus can safely operate through electromagnetic fields produced by radars, radio towers and other systems.

«Adding another tanker will help us to become even more efficient and significantly improve our ability to complete test points going forward», said Jeanette Croppi, Boeing KC-46A Pegasus tanker test team director. «We are also re-configuring one of our 767-2C aircraft into a tanker, which means we soon will have four KC-46 Pegasus tankers in test».

«This first flight is another important step for the KC-46 Pegasus program toward verifying the aircraft’s operational capabilities», said Colonel John Newberry, Air Force KC-46 System program manager. «Adding this aircraft brings key capabilities to the test fleet and helps move us closer to delivering operational aircraft to the warfighter».

To date, the program’s test aircraft have completed 1,600 flight hours and more than 1,200 «contacts» during refueling flights with General Dynamics F-16 Fighting Falcon, McDonnell Douglas F/A-18 Hornet, McDonnell Douglas AV-8B Harrier II, Boeing C-17 Globemaster III, Fairchild Republic A-10 Thunderbolt II and McDonnell Douglas KC-10 Extender aircraft.

The KC-46 Pegasus is derived from Boeing’s commercial 767 airframe. The company expects to build 179 tankers in its Everett factory.

The KC-46A Pegasus is a multirole tanker that can refuel all allied and coalition military aircraft compatible with international aerial refueling procedures and can carry passengers, cargo and patients.

General Characteristics

The KC-46A Pegasus program received Milestone C approval from Frank Kendall, the under secretary of defense for acquisition, technology and logistics, signaling the aircraft is ready to enter into production. Work is now underway to award the first two low-rate initial production lots within the next 30 days.

«I commend the team for diligently working through some difficult technical challenges», said Air Force Secretary Deborah Lee James. «The KC-46 program has made significant strides in moving the Air Force toward the modernization needed in our strategic tanker fleet».

Securing approval to begin low-rate initial production required completion of several aerial refueling demonstrations, to include refueling an F-16 Fighting Falcon, C-17 Globemaster III and A-10 Thunderbolt II off the boom, and an AV-8 Harrier II and F/A-18 Hornet off both hose and drogue systems. The KC-46 Pegasus also proved its receiver capability by taking fuel from a KC-10 Extender.

Some demonstrations were delayed due to higher than expected axial loads in the boom. Boeing installed hydraulic pressure relief valves to alleviate loads and last month all remaining demonstrations were quickly completed.

«The KC-46 is ready to take the next step», said Air Force Chief of Staff General David L. Goldfein. «Our Air Force and Boeing team stepped up to meet the recent challenges. I’m especially proud of the employees on the floor of the Boeing plant and employees of all our industry partners, who work every day to deliver game-changing capability to the warfighter. My hat’s off to them and our program leads».

The Air Force will soon award contracts to Boeing for two lots, totaling 19 aircraft, and associated spare parts for a pre-negotiated $2.8 billion combined value.

The first aircraft deliveries will be to McConnell Air Force Base (AFB), Kansas, and Altus AFB, Oklahoma. A total of 18 tankers are scheduled to be delivered by early 2018.

«I am exceedingly proud of the KC-46 program office for clearing the production hurdle», said Darlene Costello, an Air Force Service Acquisition executive. «We have crossed an important milestone, and I appreciate Boeing’s continued focus as they work to finish development prior to first aircraft delivery».

Going forward in the test program, the KC-46 Pegasus will complete a robust schedule of Federal Aviation Administration and military certification flight testing, including refueling test flights, in order to achieve certification for aircraft in the U.S. Air Force and Department of Defense inventory.

General Characteristics

The KC-46A Pegasus is a widebody, multirole tanker that can refuel all U.S., allied and coalition military aircraft compatible with international aerial refueling procedures

The KC-46 Pegasus program completed all flight tests required for the Milestone C production decision July 15 by offloading 1,500 pounds/680 kg of fuel to an A-10 Thunderbolt II.

The successful A-10 mission was the last of six in-flight refueling demonstrations required before the tanker program can request approval from Frank Kendall, the under secretary of defense for acquisition, technology and logistics, to award production Lots 1 and 2, totaling 19 Boeing KC-46A aircraft.

«It is great to see the KC-46 boom back in action and the program moving forward to a production decision», said Colonel John Newberry, the KC-46 system program manager.

The other five required air refueling demonstrations were with the C-17 Globemaster III and F-16 Fighting Falcon using the air refueling boom, the Navy’s F-18 Hornet and AV-8B Harrier II using the centerline and wing drogue systems, and the KC-46 as a receiver aircraft.

«Today’s flight marks the final step we needed to see on the boom fix in order to request production go-ahead», said Brigadier General Duke Richardson, the Air Force program executive officer for tankers. «Our joint team’s tireless efforts are paying off, preparing us for the next step of this critical need to our warfighter».

This test would not have been possible without contributions from the 412th Test Wing, 23rd Fighter Wing, 355th FW, 124th FW, 896th Test Support Squadron and 40th Flight Test Squadron, which all provided aircraft, manpower and equipment.

The Milestone C decision to begin Low-Rate Initial Production (LRIP) is expected in August.

General Characteristics

Boeing KC-46 Pegasus aircraft are now expected to arrive at their first basing locations by late summer or early fall 2017. The Boeing KC-46 Pegasus was most recently scheduled for a spring 2017 arrival at Altus Air Force Base (AFB), Oklahoma, the first formal training unit location; and McConnell AFB, Kansas, the first active duty-led KC-46 Pegasus main operating base. But after a schedule risk assessment, Air Force officials determined the fielding timeline needed to be extended.

Brigadier General Duke Richardson, the program executive officer for tankers, said, «Technical challenges with boom design and issues with certification of the centerline drogue system and wing air refueling pods have driven delays to low rate production approval and initial aircraft deliveries. Throughout KC-46 development, the Air Force remained cautiously optimistic that Boeing would quickly address these issues and meet the original goal», he continued. «However, we understand that no major procurement program is without challenges and the Air Force remains committed to ensuring all aircraft are delivered as technically required».

The multi-year tanker procurement program remains one of the service’s top priorities and the U.S. Air Force will continue to work with Boeing to find ways to mitigate delays.

«The Air Force considers the KC-46 a critical capability and it’s important to take the time necessary to get it right», Richardson said. «There is no increased cost to the government as a result of these changes».

Boeing continues to work on a solution to address the higher than expected boom axial loads recorded during C-17 Globemaster III air refueling demonstration flights.

The government now expects to make a low rate initial production decision, known as a Milestone C, in August 2016 to allow Boeing additional time to fix the loads issue and accomplish the remaining aerial refueling demonstrations with the required C-17 and A-10 Thunderbolt II aircraft. Following a successful decision, the U.S. Air Force will immediately award a contract for the first two production lots, followed by Lot 3 in January 2017.

The Boeing KC-46 Pegasus will provide improved capabilities, including boom and drogue refueling on the same sortie, worldwide navigation and communication, cargo capacity on the entire main deck floor, receiver air refueling, improved force protection and survivability, and multi-point air refueling capability.

At this time, aircraft deliveries to Pease Air National Guard Base, New Hampshire, remain unchanged at spring 2018.

General Characteristics