Introduction
On 7 November 2022 at 1852:57 Zulu, a KC-46A Pegasus (tail number 15-46070) and an F-22A Raptor (tail number 09-004183) were conducting routine air refueling operations off the coast of Florida. During a breakaway maneuver, a nozzle binding event occurred, resulting in damage to the Air Refueling Boom (ARB) Nozzle of the KC-46A.
Aircraft and Crew
The KC-46A, assigned to the 305th Air Mobility Wing at Joint Base McGuire-Dix-Lakehurst, New Jersey, was operated by a crew from the 2d Air Refueling Squadron. The F-22A, assigned to the 1st Fighter Wing at Joint Base Langley-Eustis, Virginia, was piloted by a pilot from the 94th Fighter Squadron. The total monetary value of the government loss was approximately $103,295.12.
Sequence of Events
During the refueling operation, a breakaway maneuver was initiated. As the F-22A moved forward relative to the KC-46A, the ARB nozzle became bound inside the F-22A's air refueling receptacle. The binding occurred when the boom operator made manual control inputs to the ARB, applying a radial force that caused the nozzle to exceed its structural limitations and sustain damage beyond repair.
Cause and Contributing Factors
The accident investigation board determined a single cause: Mishap Boom Operator 1 made manual control inputs to the ARB, applying a radial force that caused the nozzle to become bound inside the receiver's air refueling receptacle. The resulting forces exceeded the nozzle's structural limits, damaging it beyond repair.
Two factors substantially contributed to the mishap. First, Mishap Pilot 3 failed to account for the KC-46A's stiff boom characteristics, leading to a rapid forward movement of the F-22A relative to the KC-46A. Second, the boom operator was unable to verify that the ARB nozzle was clear of the F-22A's air refueling receptacle before making control inputs.
Investigation Findings
The investigation analyzed data from the Air Refueling Control Computer and used simulator evaluations. It also noted deficiency reports related to the KC-46A boom system and limitations in boom operator training devices. However, these were not cited as causes or factors in the mishap.
Damage
The only damage reported was to the ARB nozzle of the KC-46A, which was rendered unrepairable. No injuries or fatalities were mentioned in the report.