I'll try and help you a little. I'm not an expert but I think I can provide some answers.
Dense formations tended to work well for a variety of reasons. Among them:
- the native inaccuracy of the weapons
- lack of widespread marksmanship training
- the benefits of concentrated firepower
- vulnerability to infantry charges
- vulnerability to cavalry charges
Cavalry was a big concern during this period and the infantry would form massive squares to protect themselves. The only problem was that squares were extremely vulnerable to artillery fire.
It is interesting that you should mention armor. The armor of the day pretty much couldn't stop musketballs. Also, armor is pretty flocking expensive.
Cuirassiers-- elite cavalry-- did wear breastplates and helmets, but this was probably less to stop musketballs than to protect from bayonets and sabers, and give the men a certain *cavalier* sort of extra confidence. And they were a small percentage of most calvary forces.
As far as anti-musket armor, in theory I suppose they could have filled lots of small bags with gravel and fitted them like mail onto a leather jerkin-- but do you have any idea how heavy that would be? The sons of bitches would barely be able to waddle up to the line! And a cannonball would kill them anyway. And they would probably be too encumbered to fight off even a simple bayonet charge!
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Based on accounts I've read, cavalry charges were indeed effective, but the cavalry of the day tended to be expensive and not very numerous. They also tended to die very quickly if directly subjected to musket or cannon fire, and had near zero chance of defeating a properly-formed square.
The success of a charge also seemed to depend very heavily on three intangible elements-- a fearless, ferocious leader; high ferocity and courage among the men; and timing, timing, timing, also heavily dependent on the leader and the swift obedience of his men. The cavalry had to be the best or they were next to worthless. If the aim of the defending musketry was true and they did not panic and they presented a steady wall of bayonets and bodies, losses would be high for the attackers. Cavalry charges depended heavily on their opponents tendency to panic and run.
For that matter, so did bayonet charges. Pitched melee was not common.
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With the widespread introduction of improved rifles, cavalry became much less effective and was mostly limited to scout duty and guerilla raids. Cavalry charges continued to be viable even through the initial years of WW2, but much much less so and in much more limited circumstances.
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But to sum up, with regards to your initial questions about infantry-- musketry was not terribly accurate or deadly until improvement in rifle technology. If the men stuck together, formed a straight, orderly line, marched where they were told and fired straight ahead; they were basically safe. Unless they came under massed artillery fire. Or were the object of a sudden cavalry charge. Or were confronted with a massed column of charging infantry.
DA
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