I'm not sure if this is what you're asking for, but for real surface
modifications you could use one of the following:

1) isosurface. Probably the best choice, although it may be hard to
convert your model to it. See for example isocsg.inc by Christoph Hormann.

2) mesh. If you've already got a mesh model, you could transform the
vertices directly, perhaps combined with some subdivision in the damaged
areas.

3) A method for creating larger damage that works for every model is to
difference randomly generated parts from the model using trace.


HTH,
Florian

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