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Following the end of Italy's campaigns in East Africa, a program was started to completely re-equip the Regia Aeronautica with a new interceptor aircraft of modern design. The specifications initially called for an aircraft powered by a single radial engine, with a flight endurance of one hour, and armed with a single (later increased to two) 12.7 mm (.50 in) machine gun.
Macchi's lead designer was Mario Castoldi, the creator of several racing aircraft which competed for the Schneider Trophy, including his Macchi M.39, which won the competition in 1926. He also designed the Macchi M.C.72, which set a world speed record for seaplanes in 1934. As of 2003 this record still stood. For this fighter, Castoldi proposed a modern all-metal cantilever low-wing monoplane, with retractable landing gear, and an enclosed cockpit. The fuselage was of semi-monocoque construction, with self-sealing fuel tanks under the pilot's seat, and in the centre section of the wing. The distinctive "hump" elevated the cockpit to provide the pilot with an unobstructed view over the engine. The wing had an advanced system whereby the hydraulically-actuated flaps were interconnected with the ailerons, so that when the flaps were lowered the ailerons drooped as well.
Power was provided by the 870 hp (650 kW) Fiat A.74 radial engine, although Castoldi preferred Inline engines, and had used them in all of his previous designs. Italian industrial leaders had been instructed to concentrate solely on radials due to their better reliability.
The first prototype C.200 flew on 24 December 1937. It was followed by the second prototype early the following year. During testing, the aircraft attained 805 km/h (435 knots, 500 mph) in a dive, although it could muster only 500 km/h (270 knots, 310 mph) in level flight due to a lack of engine power. Nevertheless, this was better than the performance of the competing Fiat G.50, Reggiane Re.2000, A.U.T. 18, IMAM Ro.51, and Caproni Vizzola F.5. In 1938 the C.200 won the competition, and an initial order for 99 was placed. The G.50 was also placed in limited production, because it could be brought into service earlier. Early production C.200 aircraft showed control problems in slow-speed maneuvers and the wings were subsequently modified by Sergio Stefanutti, chief designer of SAI Ambrosini.
The C.200 began to enter service in October 1939, by which time it had been given the name Saetta (or Lightning). When Italy entered the war 10 June 1940, 156 had been delivered and some were already in front line squadrons. Although the first 240 aircraft had fully-enclosed cockpits, the subsequent variants had open cockpits at the request of the Italian pilots.
The Macchi's introduction was not well received by pilots when in 1940, the first C.200 unit, 4 Stormo stationed in North Africa, discharged the type in favour of the C.R.42. The first combat missions were flown as escorts for Savoia-Marchetti SM.79 Sparviero bombers attacking Malta in June 1940, where one C.200 was shot down by a Gloster Gladiator. By 1941, the Macchi C.200 had still not fully entered service with the result that the type did not see action in France, Africa or Britain.
The Saetta with its sturdy construction, and its agility permitted skilled pilots to effectively fight against more modern designs like the British Hawker Hurricane and the American Curtiss P-40. Its greatest weakness was the light armament of two 12.7 mm Breda-SAFAT machine guns. Although possessing good flying qualities, initially the type suffered from poor landing characteristics, and at least two pilots died in these types of accident. Macchi responded with a redesigned wing from designer Stefanutti.
In facing its main foe, the Hurricane, the C.200 Saetta was well matched. While the Hurricane was faster at sea level (450 km/h vs the C.200's 430 km/h), the Saetta could reach more than 500 km/h at 4,500 m, although speed dropped off at altitude: 490 km/h at 6,000 m and 350 km/h at 7,000 m with a maximum ceiling of 8,800 m. Comparative speeds of the Hurricane Mk.I was 505 km/h at 5,000 m and 528 km/h at 6,000 m. Over 5,000 m and at very low levels, only the huge Vokes (anti-sand) air filter fitted to the "tropical" variants slowed the Hurricane Mk.II to Macchi levels. Although the Macchi C.200 was more agile than the Hurricane, it was lightly armed, its windshield and pilot's seat were not usually armoured nor was a radio normally fitted as standard, while its flight characteristics, even if better than the G.50, were not easily mastered by the average Italian pilot.
The C.200 subsequently saw action over Greece and Yugoslavia. Fitted with dust filters and designated C.200AS, Saettas saw extensive use in North Africa. A number were also involved in operations on the Eastern Front during 1941-2 where, together with C.202s, they achieved a claimed 88 to 15 victory/loss ratio.
In an attempt to improve performance, a C.201 prototype was created with a 1,000 hp (750 kW) Fiat A.76 engine, but this was abandoned in favour of the Daimler-Benz DB 601-powered C.202. The Saetta was to have been replaced outright by the C.202 after only one year in production, but the C.200's service life was extended because Alfa Romeo could not produce enough of the RA.1000 (license-built DB 601) engines, and more C.200s were built using C.202 parts while waiting for production to increase.
The most serious handicap was the low production rate of the type at over 22,000 hours in production time due to antiquated construction technology. A total of 1,153 Saettas was eventually produced, but almost all were gone by the time of the Armistice with Italy in September 1943. Twenty-three were transferred to Allied airfields in southern Italy, and flown for a short time by pilots of the Italian Co-Belligerent Air Force.
The Saetta underwent very few modifications during its service life. Aside from the switch to an open canopy, later aircraft were fitted with an upgraded radio and an armoured seat. Some late-production Saettas were built with the MC.202 Serie VII wing, thus adding 2x 7.7 mm Breda-SAFAT machine guns to the armament. The four (including two proposed) C.200 derivates were:
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