One thing you must realise is that there is no such thing as pure iron/steel these days. Iron/steel isn't nearly as strong now as it was in medieval times. However, with that said, iron in early medieval times was so soft you could hack right through a helm with a sword and leave a nice lil mark on the skull (depending on the grade of iron used on the sword and the helm, ofcaurse). After many hundreds of years of fine tuning, however, the only use the sword had was to puncture the plate. That was very difficult, however, since the grade of steel was so hard... only blunt instruments and weighted axes had any use against plate armor in later medieval times. Makes me wonder why rapiers were so popular then and why less people wore plate (Other than it's obsene costs... a nice suit of armor would cost as much as a nice lexus does now... and a kings suit would be as much as a rols royce).
Young kid from last town has been following the PCs and doing a rather good job at it. PCs weren't expecting to be followed so weren't worried and the boy/girl was careful. Notice the follower a couple days out of town, kid ran out of food and started getting careless. Followed the 'mighty adventurers' to see if he could join them. Father is a wealthy merchant. Bring him home, bring him with, send him off? What do you do with an unwelcomed guest.