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2) Haven't done much with lasers, but I don't think you can customize the lamp or excitation spectra in any way, other than chosing different materials. Most combinations are going to be bad, and I could easily believe that only one or two are good.
3) Nukes can be improved a lot over stock, probably in more than one way. The way I've found is maximizing fusion yields, rather than relying on fission. But I suspect other paths exist. Not sure why you think compression ratio is random. I will note that as far as I've seen fission efficiency never goes above 50%, so trying to tweak compression to get past that is a waste of time.
The most likely big thing for you to be missing is enrichment, though. Always set that to the maximum allowed - the label claims it costs more, but it doesn't really and it generally makes everything better.
4) ...the HE cannon actually works? Huh. I have no idea why, it seems like it should be useless in space...
I often use titanium and vanadium-chromium-steel wheels due to mass-strength ratio and average density, though for light applications even simple aluminium may suffice perfectly (protip: magnesium is lighter than aluminium, so always check it as an option if you're using aluminium for anything, it may be cheaper and lighter while still adequate for the job; I've found it to be a good replacement for aluminium in turbopumps). I think a good starting point for dense wheels is molybdenum since it is cheap. Though other materials like tantalum & hafnia-based ceramics, depleted uranium, and tungsten are nearly twice as dense, none of them are cheap and some are extremely expensive.
3: For modules you're not familiar with, like nukes, a good starting point is to modify the stock ones to try to optimise them; once you see what effects the handles have on something that works and note what sorts of ranges the warnings start to appear at, it's easier to set up the initial parameters on your own designs. An exception to this rule is fission reactors, as hot (2500K+) ones cooled by sodium (though I've seen and replicated an ethane-cooled 2600K design) are preferable as they reduce required radiator mass substantially, but no stock reactor is built like this.
4: More armour is not always better. The dev blog has a lot of interesting articles, including this one about armour: https://childrenofadeadearth.wordpress.com/2016/08/04/raw-steel/
"Too much armor can get shocked into plasma or spallations and inflict even more damage than a thinner armor plate."
I very much doubt a mere 20kg of octogen would cause that sort of effect though, may well be a bug.
We don't have a Hulk.
Also being able to launch nukes at the Moon was a military concern back in the day (like if one side of the Cold War set up a moonbase or something, plus space was for a time viewed as 'the new high ground' with the Moon being the highest you can practically be, but of course these notions proved unfounded and being in space actually makes you quite vulnerable instead) and ultimately the basis for the technology that put people there.
Somehow I found Tungsten Carbide wheels to be good in terms of low power consumption.