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2) They might provide layered protection, but the main deck won't protect the hangar, and a hangar fire renders your carrier useless at best and has a significant risk of outright loss.
3) Google for uncertain RTW2 forum posts? AFAIK there's no official data.
4) Somewhere between no armor and a 2" frag-proof belt and deck, no armored deck. Note, late-game you're more likely to be hit by SSMs than bombs, which usually act like large HE rather than the SAP/AP anti-ship bombs.
That's why I prioritize max torpedo protection, unit machinery, engine reliability, and speed over armor protection. Spacious quarters is also preferable to armor as improved crew quality should improve damage control (not to mention flight ops/aircraft handling!).
If I can get all of that plus 70-80 aircraft at 29+ knots with tonnage to spare, then I like to add 2" splinter protection to the main belt, main deck, conning tower, and main turrets (flat-deck armor scheme, no inclined belt or mag box), and for very large carriers maybe 2" BE/DE, but IMO more armor than that is a waste of tonnage
In RTW2 I would put 60 fighters on a 100 plane capacity CV. However, I find the special squadron in RTW3 cuts into that. But it seems very useful, so I don't want to ditch it.
It'll hurt if your basically unarmored carrier eats a bomb. But two of your armored carriers eating a bomb because their CAP is insufficient will probably hurt more, not less.
Armor on early purpose-built CVs feels like a waste of potential air capacity due to displacement limits. I think a large, fast-ish, moderately-armored, heavily-gunned 1910s CA class intended for eventual conversion to armored CVLs might be viable as a fleet scout in the 20's and an armored fighter-carrier supporting the battle-line in the 30's. Improvements in surface unit speeds and armaments, as well as air wing sizes, aircraft payloads, air accuracy, not to mention improvements in fighter range and fleet tactics which allow CVs to operate in separate groups and provide CAP to BB/surface groups from a distance will all doom such a design for the scrapheap sooner than later, unfortunately.
I should clarify that it's not that I think armor is ineffective, but that the biggest strategic advantage of building large CVs is that the entire air-wing becomes much more capable over time as aircraft and tech develops. Even if you max out your intel efforts and determine that nobody drops bombs bigger than 500lbs and can figure out a way to armor your flight deck against those 500lb bombs, the next generation of aircraft will simply drop bigger bombs, more torpedoes, guided missiles, etc (and as you noted, and if the CV enjoys a long service life, SSMs will eventually overtake aircraft as the main threat), rendering that armored flight deck obsolete.
Max TP, good speed, extra insurance on the engines from UM + reliability, pile on as just about as much AA as deck space allows, then max air capacity. Add spacious accommodations and splinter protection for the machinery/magazine/command spaces when displacement limits allow. IMO this is the best balance between protection and offensive capability and future-proofing for CVs, especially considering the additional capacity required for light jets