Refueling can be a really important issue, depending on the situation, so it should not be surprising that there has been a lot of discussion of the issue.
Here is another current thread which will provide some useful information:
http://harpgamer.com/harpforum/index.ph ... entry13985
You may need to register to get in there.
Some general comments:
Each aircraft has a public (i.e. you can see it) fuel counter, which runs down as time advances. This information is available by clicking on the plane in the group or unit window. So you should at all times know whether the plane is OK or not. As long as it has more than 0% bingo fuel, it is OK. In fact, even at 0% bingo, you still have quite a big fuel reserve.
As the counter approaches 0% bingo from above, you should get a warning message. When the plane is at somewhat more than 0% bingo, the AI will attempt to return it to base. When the plane is "low" on fuel (i.e. well before it's actually at risk), the icon will start blinking. You have not mentioned any warning message. Did you get them?
I proceeded to launch an attack with all six F117A nighthawks. I refueled them and checked their range, and I found them registering fuel for over a thousand miles while only about 600 NM from target. About 550 miles later, all six Nighthawks simultaneously take the big plunge, "OUT OF FUEL!" They were running a BAI loadout which gives them about 1600 miles. Coincidently, they crashed into the sea just about 1600 miles from Diego Garcia, which makes me wonder if the AI did not get the successful refuel info despite the readout in the unit window and refuel messages?
A minor point: "over a thousand miles while only about 600 NM from target" will not be enough, unless your weapons have a 100 nm range and you don't need to take evasive action. But having over a thousand miles and running out of fuel 550 miles later suggests that the planes are flying at military throttle setting, which uses up the fuel about twice as fast as cruising.
Crashing after refueling at a distance from the base equal to the plane's nominal range is most likely just a coincidence, because the refueling process does not restore the plane to its maximum fuel capacity. See the harpgamer thread mentioned above for the details.
Does anyone know if the AI assigns a much higher rate of consumption over target perhaps, simulating speed and maneuvering losses?
In addition to what Herman said, this could conceivably depend on what you are doing near the target. Do you loiter the planes? Do you fly around looking for weak points? Obviously, this would increase fuel use. But I expect that you have already considered this. What should work in your favor, on the other hand, is that (I think) your weapons range is not considered in the plane range considerations, so that if, for example, you are using a missile with an effective range of 60 nm, then your plane actually has 120 nm worth of fuel MORE for traveling purposes.
However, Herman did mention the throttle setting. I presume that your planes are flying on cruise setting? As mentioned above, using military throttle setting uses up the fuel about twice as fast. Afterburner wastes an enormous amount of fuel.
Also, is there an indicator somewhere that I'm missing that tells how many of "X" planes a stratotanker or other tanker configs can refuel from bingo to full, or something similar? I know the AI gauges things to some extent because it won't allow inclusion in a launch for a plane(s) unless there are adequate numbers of tankers/gals to provide fuel resources for the mission. However, that doesn't help me guaging for a tanker mission launched (i.e. from the carrier)to intercept a strike force for refueling. Does the stratotanker deplete the fuel available for other aircraft as it loiters on station, or are the refuel stores dedicated?
These questions are answered in the harpgamer thread mentioned above. Let us know if you can't access that info, and someone will make arrangements.
Lastly, how many times per mission can a plane be refueled? Any limits or increased chance of mishap, engine failure, or fueling failure as the number increases?
Pilot fatigue ... this is you. If there is a non-zero chance per refuel instance that you (the pilot) fail to call in a tanker, then more refuel instances increase the total probability of crashing. [>:] [:D]
Thanks for the all the help. Until I can get a handle on these fueling/range problems, I'm wasting my time planning strategies...
Some final comments.
You may be looking at one or more bugs, which could be in the game engine, database, or scenario. And yet, all of those would appear to be inconsistent with all the other null information. That is to say, most people don't report refueling problems, which means that the system generally works properly. So the explanation is either simpler or more complex than a simple bug.
One additional suggestion I have is that you monitor the fuel status of your planes on an ongoing basis (i.e. the pilots are reading their fuel gauges in real time, instead of relying on some higher-up telling them that they have enough fuel at the beginning of the mission). That way, you will see the problem before it arises, instead of when the planes crash. If the scenario is small enough, this should be possible.