SCOTT AIR FORCE BASE, Ill. -- Air Mobility Command has released the results of three accident investigation boards involving KC-46A Pegasus aircraft. The investigations stem from incidents involving aircraft assigned to the 305th Air Mobility Wing at Joint Base McGuire-Dix-Lakehurst, N.J., on Oct. 15, 2022, and Nov. 7, 2022, and to the 22nd Air Refueling Wing at McConnell AFB, Kansas on Aug. 21, 2024.
“The KC-46 tanker fleet will sustain our air refueling mission capabilities for decades to come,” said Lt Gen Rebecca Sonkiss, AMC deputy commander. “Challenges with adding a new aircraft to the fleet are not uncommon but we do not take these incidents lightly. We have used the lessons learned to refine our KC-46 operations, including focused training and guidance while partnering with the contractor to implement long-term solutions.”
Early indicators and lessons learned allowed Air Mobility Command to take prudent measures including specified training for aerial refuelings involving fighter aircraft and increasing the refueling envelope from six feet to 10 feet. The adjustment gives boom operators additional time to react during critical situations as well as better visual cues of receiver aircraft.
On Oct. 15, 2022, a KC-46A Pegasus assigned to the 305th Air Mobility Wing and operated by the 2nd Air Refueling Squadron, Joint Base McGuire-Dix-Lakehurst, New Jersey and an F-15E Strike Eagle assigned to the 4th Fighter Wing and operated by the 335th Fighting Squadron, Seymour Johnson AFB, North Carolina were conducting routine air refueling operations. During the mishap, a nozzle binding accident occurred during a breakaway which resulted in the air-refueling boom (ARB) striking the tail section of the KC-46A.
There were no fatalities, injuries, or damage to civilian property. The estimated damages to the aircraft were $8,307,257.93.
The accident investigation board, led by Col Chad Cisewski determined, based on the preponderance of evidence, multiple factors substantially contributed to the mishap. Due to a limitation of the ARB control system, the boom operator inadvertently placed a radial force on the ARB that caused the nozzle to become bound in the receiver’s receptacle. The limitation of the automated boom control system led to the ARB into an uncontrollable state during its upward motion toward the aircraft tail substantially contributing to the mishap.
Further, the F-15E pilot did not consider the KC-46A stiff-boom characteristics, which calls for them to use significantly more fore-aft thrust input to move the boom telescope in and out while in contact, substantially contributing to the mishap.
On Nov. 7, 2022, a KC-46A Pegasus assigned to the 305th Air Mobility Wing and operated by the 2nd Air Refueling Squadron departed Naval Air Station Cecil Field, Florida to refuel an F-22A Raptor assigned to the 94th Fighter Squadron, Joint Base Langley-Eustis, Virginia in support of a joint-force training exercise from Tyndall Air Force Base, Florida.
During the second air refueling attempt of the sortie, the KC-46A experienced a nozzle binding event during a breakaway with the F-22A, which resulted in damage to the ARB nozzle. The bound forces exceeded the structural limitations of the ARB nozzle, damaging the nozzle beyond repair.
There were no fatalities, injuries, or damage to civilian property. The estimated damages to the aircraft were $103,295.12.
The accident investigation board, led by Col Justin Ballinger, determined, based on the preponderance of the evidence, multiple factors substantially contributed to the mishap. The boom operator’s failure to verify that the ARB nozzle was clear of the F-22A’s air refueling receptacle prior to making ARB control inputs, substantially contributing to the mishap. The boom operator made manual control inputs to the ARB which caused a radial force to be applied to the ARB nozzle, causing it to become bound inside the F-22A’s refueling receptacle. Additionally, the F-22A pilot did not consider the KC-46A stiff-boom characteristics, causing a rapid forward movement of their aircraft relative to the KC-46A, substantially contributing to the mishap.
On August 21, 2024, a KC-46A Pegasus assigned to the 22nd Air Refueling Wing and operated by the 931st Air Refueling Wing departed Travis Air Force Base, California to refuel an F-15E assigned to the 366th Fighter Wing in support OPERATION NOBLE EAGLE.
During the fourth air refueling attempt of the sortie, the KC-46A experienced nozzle binding of the boom in the F-15E receptacle. Upon release, the boom rapidly flew upward, striking the bottom aft portion of the KC-46A, and violently oscillated left and right.
The boom striking the aircraft and ensuing forceful oscillations resulted in critical failure of the boom shaft structure, portions of which detached from the KC-46A in flight.
The KC-46A crew declared an in-flight emergency and returned to Travis AFB. Emergency response personnel met the crew upon arrival.
There were no fatalities, injuries, or damage to civilian property. The estimated damages to the aircraft were $14,381,303.
The accident investigation board, led by Col Diane Patton, determined, based on the preponderance of the evidence, that the mishap was caused by the boom operator's control inputs, coupled with the receiver aircraft’s excessive closure rate and instability, which led to the boom striking the tanker aircraft.
While another nozzle-binding incident occurred on July 8, 2025, the circumstances remain under investigation. Upon completion, the Command will determine if further mitigation efforts are required.
The full versions of the investigation reports can be found here:
15 OCT 22, AMC, KC-46A, JOINT BASE MCGUIRE-DIX-LAKEHURST, AIB REPORT
7 NOV 22, AMC, KC-46A, JOINT BASE MCGUIRE-DIX-LAKEHURST, AIB REPORT
21 AUG 24, AMC, KC-46, MCCONNELL AFB, AIB REPORT
For more information, please contact Air Mobility Command Public Affairs at (618) 229-8587.