US lawmakers cap new USAF tanker buys amid concerns over Boeing KC-46 deficiencies

Jack Flynt, an Air Force veteran who flew both the KC-135 and later transitioned to the KC-46A, commented on his experience: "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. The tanker enables so many of the other missions to do their job. There is no other airframe out there where you get to affect so many lives at once.”

Despite slowing down on Pegasus acquisitions, Congress seeks an overall increase in tanker capacity. The draft 2026 National Defense Authorization Act proposes raising the minimum required number of USAF tankers from 466 to 504 by 2027, as reported by Flight Global (https://www.flightglobal.com/defence/us-lawmakers-want-more-tankers-fewer-kc-46s-until-deficiencies-fixed/155119.article). Additionally, Congress will enforce restrictions on retiring Boeing KC-10 tankers if fleet minimums for combined KC-135s and KC-46s are not met by that year.

Any retired Boeing KC-10 aircraft must be stored in flyable condition with their inflight refueling booms intact; they cannot be used for spare parts while in storage.

The KC-46 offers several improvements over previous models. It can carry up to 54 patients during aeromedical evacuations, features a flexible cargo system adapted from commercial freighters, and is equipped with advanced refueling technology such as a fly-by-wire boom and panoramic Remote Vision System (RVS 2.0). Its defensive systems include radar warning receivers, electronic warfare suites, decoys, secure communications links like Link-16 and SATCOM, as well as modernized radios.

Flight deck upgrades provide large-format displays, dual heads-up displays (HUDs), synthetic vision capability, and compliance with civil aviation tracking standards. The engines are significantly more fuel-efficient compared to those on older tankers—by about 20–25%—and benefit from improved maintenance features that reduce repair times by over 30%.

These developments come as part of broader efforts by both Congress and military planners to ensure continued air refueling capacity while addressing technical challenges faced by new aircraft entering service.