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What became the Catalina resulted from an October 1933 Navy contract for a new water-based patrol plane. Originally designated XP3Y-1, the prototype and its Douglas-built rival, the XP3D-1, were the first Navy flying boats with cantilever wings. The all-metal XP3Y-1 mounted its huge parasol wing, with retractable wingtip floats, on a pylon above the fuselage. To better reflect its combat role, the P3Y was redesignated as PBY in 1936.
Russia obtained three PBYs in 1938 and began building their version soon after, designated GST. An amphibious variant, the PBY-5A, appeared in November 1939 and incorporated retractable landing gear for both water and land-based operations. Together with the non-amphibious PBY-5, this version became the most-produced design with over 1,500 built.
The urgent need for patrol planes in World War II led to orders from Britain, which gave the PBY its "Catalina" nickname. U.S. and Canadian plants built the PBY, including the Naval Aircraft Factory, which produced the PBN Nomad with a redesigned tail and other improvements including larger fuel tanks, 50% increased range and stronger wings permitting a 2,000 lb (908 kg) heavier gross weight. An auxiliary power unit was installed, along with a modernized electrical system, and the weapons were upgraded with continuous-feed mechanisms. These modifications were incorporated on the last U.S. variant, the PBY-6A. Catalinas were exported to France, Russia and the Netherlands East Indies, and also transferred to the U.S. Army Air Forces as the OA-10. They filled many roles, including coastal, long-range and anti-submarine patrol, bombing and air-sea rescue. In the Pacific, their vulnerability to enemy fire led to a change to more successful nighttime operations, in which "Black Cats" attacked Japanese shipping. Catalinas flying "Dumbo" missions rescued thousands of downed airmen in the role for which they are perhaps best remembered.
The Royal Australian Air Force ordered its first PBY-5 Catalinas in 1940. By the end of the war the RAAF had taken delivery of 168 Catalinas. The RAAF used Catalinas in a wide range of roles including reconnaissance and anti-submarine patrols, offensive mine-laying and air-sea rescue. In addition, RAAF Catalina aircraft were used to transport Australian personnel back to Australia at the end of the war. The RAAF retired its last Catalina aircraft in 1952.
Canada had its own close associations with the Catalina, both as a manufacturer and customer. Under an agreement reached between the Canadian and US governments, production lines were laid down in Canada, by Boeing Aircraft of Canada (as the PB2B-1) in Vancouver, and by Canadian Vickers (PBV-1) at the Canadair plant in Cartierville. Canadian aircraft were known as the "Canso". Canadian squadrons flew Cansos on both sides of the North Atlantic as well as in the Indian Ocean.
From 1942 New Zealand used 56 Catalinas in the South Pacific, to replace the Short Singapore with the Royal New Zealand Air Force's 5 Squadron and 6 Squadron, initially operating out of Hobsonville and Fiji on maritime patrol and air-sea rescue roles. Additional aircraft were used by 490 (NZ) Squadron in the anti submarine role during the battle of the Atlantic. 490 squadron operated Catalinas out of Jui in East Africa from 1943 until they were superseded by Short Sunderlands in 1944. When Sunderland MR Mk 5s replaced the New Zealand based Catalinas, two of the ex-RNZAF machines was transferred to TEAL for crew training - one, ZK- AMP - made pioneering air survey flights throughout the Pacific. The last RNZAF Catalinas were retired in 1953 and all had been sold or scrapped by the end of 1956.
The Soviet Union had shown an interest in the aircraft and this resulted in an order for three aircraft and the negotiation of a licence to build the type in Russia. When these three machines were delivered they were accompanied by a team of Consolidated engineers who assisted in establishment of the Russian production facilities. This aircraft model, designated the "GST", was powered by two Mikulin M-62 or Shvetsov ASh-621R radial engines with a power rating of 900 to 1,000 hp (or 671 to 746 kW) . The first of these GSTs was put into service towards the end of 1939. It is estimated that hundreds more were put into service with the Soviet navy. Russia also received 137 of the PBN-1 Nomad variant of the Catalina built by the Naval Aircraft Factory in Philadelphia along with 48 PBY-6As under the Lend-Lease Act .
Three Catalina (Canso) amphibians, built by Canadian-Vickers, were bought by the Swedish Air Force in 1947. The Swedish designation was Tp 47. After modifications for their new post-war missions, they were based at Wing F2 at Hägernäs near Stockholm and were used mainly for air and sea rescue service. Also reconnaissance missions were flown.
The Tp 47 was equipped with a radar type PS-19/A. The aircraft had a crew of five and had also room for six stretchers. It was powered by two Pratt & Whitney R-1830-92 Twin Wasp 14-cylinder radial engines of 1.200 hp each. The aircraft carried no armament.
The British Air Ministry purchased a single aircraft for evaluation purposes, the Model 28-5. This was flown across the Atlantic Ocean to the Marine Aircraft Experimental Establishment at Felixstowe on the East Anglian coast of England in July 1939. With the outbreak of war anticipated, the trials were terminated prematurely, and an initial 50 aircraft were ordered under the designation "Catalina I". These aircraft were similar to the US Navy's PBY-5s except for the installation of British armament. The name "Catalina" had been used by Consolidated for their commercial sales prior to the British order, and was eventually adopted by the US Navy on October 1, 1941.
Initial deliveries of the Royal Air Force's Catalinas began in early 1941 and these entered service with No. 209 and No. 240 squadrons of Coastal Command. In all, nine squadrons of Coastal Command were equipped with the Catalina, as were an additional 12 squadrons overseas. The total acquisition was approximately 700 spread over the following designations: Catalina Mk.I, Mk.IA (PBY-5A amphibian in RCAF service only), Mk IB, Mk II, Mk III, Mk IVB (Canadian built PBY-5, the PB2B-1), Mk IV, and Mk VI (a PBN-1 style tall tail version built in Canada). The Catalina Mk V which would have been PBN-1s were a cancelled order.
In British service the Catalina was fitted with .303 inch guns, typically a Vickers K at the front and Browning MGs in the waist positions. Some received the Leigh light to aid anti-submarine warfare by night.
Between 1940 and 1945 seven former RAF examples were used by BOAC (two for a Poole to Lagos service), and Qantas (five for a Ceylon to Perth service).
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