Just a thought here, why does armor have to be a flat % anyways. The way I understand it, currently:
RealDamage = max(.2 * Damage, Damage - Armor)
This results in a minimum 20% of damage dealt when damage is less than 1.2 * Armor, but armor quickly becomes negligible to larger shots.
Not a flat % system. However what about something like this:
RealDamage = Sqr(Damage) / (Damage + Armor)
In this example:
When you have lower damage than armor, than armor your damage drops off.
When you have equal damage to the armor, damage dealt is 50%
When you have higher damage than armor, you deal an increasingly more amount of damage with little lost. Eventually reaches a point where it approaches the current system of Actual Damage = Damage - Armor.
What you get from this formula is: Damage * ratio of damage to armor. Armor piercing effects will shift the spectrum by simply reducing armor like it currently does allowing for more damage to go through rather than being simply being absorbed by the armor. Then you just normalize HP to about 50% of it's current value, or you could double damage.
This way ships within a tier can be evenly classed, but not have their armor completely be ignored by a higher tier or two (one tier higher 34% more damage, two is 50% more). After a certain point though it becomes a landslide.
Some datapoints to help you see the curve this would create on damage to armor ratio. All work is done in % of armor the incoming damage represents vs. % of damage adjustment
10% = 9%
20% = 16%
30% = 23%
40% = 29%
50% = 33%
60% = 38%
70% = 41%
80% = 44%
90% = 47%
100% = 50%
110% = 52%
120% = 55%
130% = 57%
140% = 58%
150% = 60%
160% = 62%
170% = 63%
180% = 64%
190% = 66%
200% = 67%
300% = 75%
400% = 80%
500% = 83%
600% = 86%
700% = 88%
800% = 89%
900% = 90%
1000% = 91%
2000% = 95%
3000% = 97%
4000% = 98%
5000% = 98%
Edit: Just thought I'd throw in a few examples here of how the new armor system would work.
Bomber Mk 1 vs Bomber Mk 1
9760 damage, 1200 armor. Actual damage = 8691 (11% damage absorbed)
Bomber Mk 1 vs Bomber Mk 1 with armor booster
9760 damage, 1200 x 3 armor. Actual damage = 7130 (27% damage absorbed)
Bomber Mk 2 vs Bomber Mk 1
19560 damage vs 1200 armor. Actual Damage = 18429 (9% damage absorbed)
Bomber Mk 2 vs Bomber Mk 1 with armor booster
19560 damage vs 1200 x 3 armor. Actual Damage = 16519 (16% damage absorbed)
Bomber Mk 1 vs Bomber Mk 2
9760 damage, 2400 armor. Actual damage = 7833 (20% damage absorbed)
Bomber Mk 1 vs Bomber Mk 2 with armor booster
9760 damage, 2400 x 3 armor. Actual damage = 5617 (43% damage absorbed)
Bomber Mk 1 vs Bomber Mk 5
9760 damage, 6000 armor. Actual damage = 6044 (38% damage absorbed)
Bomber Mk 5 vs Bomber Mk 1
48800 damage, 1200 armor. Actual Damage = 47628 (2.4% damage absorbed)
Bomber Mk 1 vs Missile Frigate Mk 5
9760 x 6 damage, 1500 armor. Actual Damage = 57097 (2.5% damage absorbed)
Bomber Mk 1 vs Missile Frigate Mk 5 with armor booster
9760 x 6 damage, 1500 x 3 armor. Actual Damage = 54381 (7.2% damage absorbed)
From these examples you can see that armor boosters can become more relavent without ruining damage bonuses. Actual final armor values may need tweaking.