Following the latest statements from the Air Mobility Command (AMC) Chief, General John D. Lamontagne, the United States Air Force (USAF) is evaluating the launch of a new service life extension program for the KC-135 Stratotanker refueling aircraft. The goal is to sustain the current incorporation rate of 15 of these aircraft per year. If approved, this decision—still under review—could extend the fleet’s service life, which already exceeds 60 years, to nearly 100 years.
For decades, the KC-135 has been the backbone of the U.S. Air Mobility Command’s aerial refueling capabilities. This, along with other considerations, has led the Air Force to explore a new project to replace them under the concept of a new generation of refueling aircraft, designated as the Next-Generation Air Refueling System (NGAS). However, with the retirement of the KC-10 Extender and the Boeing KC-46 Pegasus facing a delivery suspension and years of accumulated delays, USAF officials are considering a comprehensive review to keep the KC-135s operational. In this context, Lamontagne stated that the feasibility of this program and its budget will determine whether the Air Force considers other options to extend the KC-135’s service life.
Nevertheless, the high command noted that the plan’s future will partly depend on the Trump administration’s decisions regarding the Next-Generation Air Dominance (NGAD) air superiority program and the requirements for the future fighter aircraft. An Analysis of Alternatives (AOA) on the future of the Air Force’s aerial refueling fleet is completing its “final touches” and is expected to be completed by the end of March, he indicated. Additionally, in the past few hours, the President of the United States officially announced that Boeing has been selected to develop the future sixth-generation fighter, designated the “F-47”.
As of today, the KC-135 Stratotankers have undergone multiple modernizations and service life extensions, the most recent in 2010 with the Block 45 upgrade, which enhanced the tanker’s capabilities and prepared it to operate until the 2040s. Over the years, the entire fleet has been equipped with new engines, structural redesigns, and several avionics updates since its original manufacturing.
The general did not specify how extensive the Service Life Extension Program (SLEP) might be but emphasized that such programs are only implemented if the Air Force determines that costs can be recovered within 10 to 20 years through reduced maintenance expenses, spare parts consumption, fuel efficiency improvements, or other factors.
Meanwhile, in recent weeks, Boeing and the U.S. Air Force announced that deliveries of the new KC-46 Pegasus, designed to replace the aging KC-135 Stratotankers and the retired KC-10s, have been suspended due to a series of cracks detected in the hinge brackets of the flaps on four aircraft. This delay will require an inspection of 89 already-delivered aircraft at the fleet level before determining the next steps. Additionally, the current situation of the KC-46 remains urgent due to years of accumulated delays. So far, 11 of the 50 KC-46s inspected have shown structural cracks. Another 39 aircraft are expected to be examined within the next two weeks.
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