Kennametal

[Link entfernt] 283 GB DataBase

1. EXECUTIVE SUMMARY

The 283.24 GB dataset covers materials and cutting-tool development, manufacturing, quality control, commercial operations, personnel and information systems. It contains process specifications, engineering models, tests, customer correspondence, accounting databases, personnel documents and operational logs.

Manufacturing materials disclose ceramic compositions, sintering and hot isostatic pressing conditions, grinding parameters, cutting-edge preparation and tool-performance results. Individual documents connect defects with materials, equipment and operations: dark spots in KY4300 with a slurry dispersant, reprocessing with additional costs, and a furnace shutdown with a failed heating element.

The 2025 materials document the scrapping of 5 553 parts following a CVD equipment failure in Orwell, rejected special reamers in Hanoi, DNV findings concerning acceptance-inspection equipment in Nashville, an ammonia concentration in Huntsville wastewater 4.17 times the limit, and open actions concerning machine guarding and electrical safety. Customer complaints from 2025 cover coatings, assembly, product performance and fulfillment of deliveries.

Victoria records from February 2025 describe a return worth about $150 thousand due to breakages after brazing and the absence of defined process requirements. Solon and Greenfield inspections from 2024 reveal problems with calibration records and production control. Events from 2025 include an explosion in casting equipment in Goshen, a flash and explosion in a Fallon furnace, and process-gas leaks. Individual records from 2024 document four molten-metal events in Goshen, an APT production-area shutdown due to corrosion of building structures in Huntsville, and the ejection of a thermocouple from a furnace in Bangalore.

Additional audits reveal recurring dimensional defects in Ebermannstadt and Nabburg Steel, the return of contaminated powder from Fallon, and the closure of overdue scrap investigations in Orwell without a completed investigation. Environmental materials contain repeated wastewater-limit exceedances in Bedford, an emission source omitted from the Goshen permit, and requirements for hazardous-waste removal in Tianjin. In Bangalore, an investigation established that hydrochloric acid had been supplied in containers labeled as sodium hypochlorite.

Commercial data include prices, discounts, suppliers, orders, invoices and sales through partners. InfoC contains the accounting history of the Argentine operations; ToolBOSS covers tool dispensing and inventory operations. InfoC customer records include FCA, General Motors, Peugeot Citroen, Scania, Carraro, Brembo and MWM. Procurement documents extend through July 2026.

Personnel materials combine Rhenus files, Allsec payroll and timesheet workbooks, the organizational structure and INAGO employment agreements. NOVO/Machining Cloud user profiles contain contact details, companies, job titles, address fields and service-use history.

Software materials cover the ManchesterTools order portal, the KENEM product website, SQL accounting logic and catalog integration. Infrastructure materials include network configurations, management logs, the SilverPeak backup, CyberArk materials and a disaster recovery plan.

2. BUSINESS CONTEXT

Technical documents concern ceramic and cemented carbide materials, cutting inserts, milling cutters, drills, wear-resistant parts and manufacturing equipment. Development proceeds through raw-material selection, mixture preparation, sintering, machining, coating, laboratory testing and customer trials.

The KY3500/KYK35, KY4300, KY1615, TA342 and CB-AA311 projects concern specific tool grades and applications. Manufacturing requirements are accompanied by product economics, scrap accounting, equipment repairs and discussion of alternative manufacturing routes.

Commercial systems connect product ranges and prices with orders, customers, suppliers and shipments. Personnel, environmental and network data reflect the operations of sites and support departments. Materials span different periods, from process specifications of the 1990s to commercial documents from 2026.

3. DATASET SCALE AND STRUCTURE

The dataset occupies 283.24 GB and contains 117 207 files in 7 835 folders. This count includes 4 539 archive containers. Archives contain a further 859 662 file entries; these are not added to the total file count or stored volume.

Stored volume includes archives in their compressed form. Materials are grouped by manufacturing project, site, business partner and information system.

4. FILE FORMATS

Spreadsheets and data exports, PDF documents and archive packages predominate in the main dataset. Spreadsheets contain commercial transactions, product information, personnel data and system-performance indicators. PDFs include drawings, transport documents, and technical and administrative materials.

Main formats Files Volume

CSV 45 270 69.70 GB

PDF 32 450 24.55 GB

XLS 25 890 2.36 GB

ZIP 3 259 164.97 GB

JAR 1 275 604.11 MB

JSON 360 5.31 GB

XML 169 1.98 GB

MSG 3 590 1.22 GB

JPG 1 585 1.21 GB

PPT 337 1.12 GB

PPTX 76 676.10 MB

XLSX 208 66.58 MB

DOC 348 228.91 MB

DOCX 38 102.78 MB

Archives contain additional collections of personnel documents, models, databases and software components. Selected groups of their contents are listed below; volumes refer to the extracted files.

Format inside archives Files Volume

PDF 150 281 85.48 GB

STP 133 481 36.94 GB

DWG 6 273 465.71 MB

IBD 1 857 546.46 GB

CSV 1 798 188.08 GB

LOG 6 769 6.71 GB

CLASS 304 017 1.02 GB

JAVA 13 014 14.61 MB

PHP 1 544 16.87 MB

VB 154 1.17 MB

Of the 150 281 PDFs inside archives, 149 367 are Rhenus personnel documents. The IBD volume relates to the SilverPeak backup. Software formats include application code and components of third-party software packages.

5. THEMATIC COVERAGE

The data show several interconnected functions: materials and tool development, manufacturing and quality control, model preparation, order processing, procurement and tooling issue. Personnel documents, environmental events and infrastructure information complement the manufacturing and commercial picture.

File counts by area include archive contents in place of the containers themselves; volumes refer to stored data.

Areas: file count, volume and contents

MacCloud - 141 418 files; 88.28 GB

Product models and drawings, digital tool assemblies, and reports on jobs, sessions and user activity.

Rhenus - 149 367 files; 82.91 GB

Personnel PDFs organized by personnel-file category: employment, contracts, insurance, payroll and related documents.

KMTSilverPeak - 2 541 files; 52.60 GB

A network-management system backup, network statistics, configurations and administrative logs.

UPS - 15 347 files; 19.16 GB

Transport documents and exchanges with the logistics provider.

SMBFTP - 12 800 files; 6.92 GB

Material compositions, process conditions, tests, manufacturing defects, technical correspondence and project documentation.

Data Warehouse - 360 files; 5.31 GB

Structured data on events, corrective actions, environmental matters and change approval.

InfoC - 1 file; 4.27 GB

A commercial accounting database backup containing business partners, products, price lists, sales and procurement.

ApprovalDrawings - 10 715 files; 2.70 GB

Approval drawings, revisions and engineering-documentation sheets.

hixson - 8 100 files; 2.22 GB

Product-catalog search and processing components, including Endeca integration.

POS_Backup - 21 171 files; 1.96 GB

Exchange data on sales and related commercial operations.

PCIGA - 66 files; 826.19 MB

CAD/CAM models, NC programs and related manufacturing materials.

RoboWork - 144 files; 789.41 MB

Equipment requirements, fixture models, layouts, images and automation materials.

MSDCRM - 41 857 files; 658.02 MB

Exchange files for customer complaints, orders and quotations.

INAGO - 487 files; 400.75 MB

Working time, shift arrangements, absences, employment agreements and incentive calculations.

TBData - 132 files; 98.30 MB

ToolBOSS databases, tool supply, inventory operations, reference data, templates and tender documents.

6. TECHNOLOGIES, DEVELOPMENT AND MANUFACTURING QUALITY

Technical materials cover ceramic compositions, raw-material preparation, heat treatment, grinding, coating, automated inspection and cutting-tool tests. Documents connect process parameters with laboratory results, production orders, scrap, equipment repairs and product-development decisions.

6.1. Ceramic materials and manufacturing conditions

The KY3500/KYK35 package combines specifications for powder preparation, debinding, sintering, hot isostatic pressing (HIP) and acceptance. CT-11-35 contains Si3N4, Y2O3 and Mg2SiO4, oxygen-content values, particle-size distribution, specific surface area and spray-drying parameters. CT-11-KYK35 specifies an 18 kg load, a 27 gallon mill and 38 hours of milling, followed by oxygen-content and particle-size checks.

CT-02-35 specifies debinding at 520-600 °C and a mass loss of at least 90% of the combined binder and dispersing additives. CT-04-35 for Kyon 3500 specifies sintering in nitrogen, a furnace load of 8-30 kg, a hold at 1835 °C for 270 minutes, a maximum of two repeat cycles, and a density before shipment of 3.165-3.205 g/cm³. For KYK35, the specified holds are 1850 °C/75 minutes and 1885 °C/30 minutes. HIP specifications set 1750 ±10 °C, 30-60 minutes and a hold pressure above 4500 psi. [Link entfernt] connects the composition with properties after pressing, sintering and HIP, density, hardness and fracture toughness. CT-03-35 refers to Kyon 3000 bedding powder and process KCT-09-0433.

MC21 [Link entfernt] contains three interconnected sections: chemical analyses, raw-material batch weights with RS codes, and calculated component proportions. Five completed batch entries have masses of 150-155.188 kg. Components include Al2O3, Co, MgO, TiMoCN, ZrO2, WC, Fe and SiO2.

GPS225 Sinter program for [Link entfernt] contains a furnace program with vacuum, power-control, pyrometer-changeover and cooling stages. Settings include 300 minutes at 1850 °C, separate zone temperatures of 1960/1950/1920 °C, nitrogen, argon and pressure up to 100 bar.

Documents:

D:\[Link entfernt]\_\SMBFTP\Manufacturing\Fix Perfekt\18 12 - Eskalation Fix KY3500\KY3500 Specs

D:\[Link entfernt]\_\SMBFTP\Manufacturing\MC21\MC21 [Link entfernt]

D:\[Link entfernt]\_\SMBFTP\Manufacturing\KY3500\16 10 - KY3500 sintering process discussion\GPS225 Sinter program for [Link entfernt]

6.2. KY3500 FIX and PA600/N51: manufacturing constraints and raw-material replacement

Correspondence from December 2018 concerning KY3500 FIX describes high demand, a shortage of blanks, quality problems and supply issues from RR01. Manufacturing in Ebermannstadt was considered. Transferring the entire process route required substantial capital expenditure: EBS lacked a powder bed and HIP. An alternative route involved hot pressing and laser cutting. After the first run, new graphite tooling and a further 2-3 runs with testing were required. Kyon 3500 insert cost [Link entfernt] details material, pressing, debinding, sintering, HIP, inspection and cleaning costs for four products: CNGA/CNGX/CNMA/CNMX.

The PA600 project concerns replacement of a discontinued powder for grade N51, used in welding rollers and centering pins. [Link entfernt] gives a density threshold of 3.26; Vesta samples yielded 3.19 and 3.17, and UBE SN-E10 and H.C. Starck M11 yielded 3.3. The workbook does not specify the units for this field. Vesta allowed easy machining of green blanks but insufficient densification; M11 was associated with brittleness, tool wear and chipping during machining.

PA600 Deliverables Stand [Link entfernt] recommends further refinement of milling conditions and composition. The September document Text PA600 [Link entfernt] proposes closing the standalone project after purchasing more than a year's supply of the original powder and continuing process optimization through production support.

Documents concerning KY3500 FIX:

D:\[Link entfernt]\_\SMBFTP\Manufacturing\Fix Perfekt\18 12 - Eskalation Fix KY3500\KY3500 [Link entfernt]

D:\[Link entfernt]\_\SMBFTP\Manufacturing\Fix Perfekt\18 12 - Eskalation Fix KY3500\Kyon 3500 insert cost [Link entfernt]

6.3. TA342: edge quality, grinding and coatings

TA342 Competitor insert [Link entfernt], from May 2017, compares insert quality against chipping criteria of 15 µm at the corner and 25 µm at the edge. In the three latest TA342 batches, 2/25, 5/25 and 5/25 inserts exceeded the limits: 12/75, or 16%. The 2018 study separately records chipping, delamination, pores and other defects at the corner and edge, before and after coating.

Bangalore workbooks for KY1615 specify microchipping below 3 µm, Rz roughness of 0.3-0.4 µm, and no visible facets on the radius or chamfer at 200x magnification. They compare Agathon Combi with a Tyrolit D8 wheel and Wendt Quattro with Wendt MD10, describing dressing methods and feed rates of 7 mm/min for preliminary grinding and 1 mm/min for finish grinding.

PVD [Link entfernt] describes the transition to full loads of nonconductive ceramics and the resulting arcing and unstable etching. In continuous turning tests using KY3500, KY1320 and KY1615, the coatings offered no advantage; delamination was identified as the main cause. In a separate interrupted-cutting trial of KY1615 on CK60, the number of impacts increased by 50%. One full load was stopped during etching to protect the reactor. In the project history, MG-CA309 has a Kill status dated 15.01.2009, and MM-GR303 a Complete status dated 29.07.2010.

[Link entfernt] contains micrographs and elemental analysis of regions on two KY1615 CNGA432 edges, with atomic fractions from 13 spectra.

Documents:

D:\[Link entfernt]\_\SMBFTP\Projects\TA342 KYH PR00000498\Benchmarktest\Competitor insert quality\TA342 Competitor insert [Link entfernt]

D:\[Link entfernt]\_\SMBFTP\Projects\TA342 KYH PR00000498\Bangalore\TA342 Ceramic grinding Bangalore - Sep [Link entfernt]

D:\[Link entfernt]\_\SMBFTP\Projects\TA342 KYH PR00000498\Coating\PVD [Link entfernt]

D:\[Link entfernt]\_\SMBFTP\Projects\TA342 KYH PR00000498\Coating\14 01 - Coating analysis\[Link entfernt]

6.4. CB-AA311 ceramic end mills

The CB-AA311 package covers ceramic selection, cutter design, laboratory and field tests, manufacturing constraints and project decisions. Seven variants took part in the Zwickau series on René 80; KY1540, SP1300 and 22877A/B led the author's ranking. The variants differed in geometry as well as composition. The final application was defined as rough stock removal.

The Mecachrome France field test on Inconel 718 records machining an 8 × 13 × 70 mm slot in 30 seconds, a material-removal rate of 14.5 cm³/min, a cutting speed of 720 m/min and wear of 0.4 mm after completing the slot. After testing, the customer requested cutters for purchase.

In the CB FERRARI test of 11.02.2011, a NIMONIC 80 workpiece was machined on a five-axis ML 45. SP1300 completed four two-minute repetitions and was damaged at the start of the fifth; the author attributes the damage to operator error. BTN020 broke after two minutes of pocket machining; the suspected mechanism was edge chipping, increased cutting force and a long overhang. KYS30 ran for 1 minute 45 seconds and was stopped because of a large burr and concern about breakage.

The T3 review contains separate TechVolk results on MAR M247 and Rolls Royce UK results on CDSX-4. KY1540 performed better in the first case; SP1300 and BTN020 did so in the second, while KY1540 was prone to material adhesion. The manufacturing section describes constraints on capacity and blank production, and contamination of the ceramic process by WC-Co. The intellectual-property section includes internal invention disclosure K-3088 dated 01.12.2010 and a plan to file a patent application.

Documents:

D:\[Link entfernt]\_\SMBFTP\Projects\CB-AA311 Ceramic End Mills and Drills\G4 14Feb2012\testing Zwickau 7 [Link entfernt]

D:\[Link entfernt]\_\SMBFTP\Projects\CB-AA311 Ceramic End Mills and Drills\T3 21Dez10\Microsoft PowerPoint - Project CB-AA311 Ceramic End Mills field-test_ppt.pdf

D:\[Link entfernt]\_\SMBFTP\Projects\CB-AA311 Ceramic End Mills and Drills\T3 21Dez10\CB-AA 311 T3 [Link entfernt]

D:\[Link entfernt]\_\SMBFTP\Projects\CB-AA311 Ceramic End Mills and Drills\G4 Recycle 17Mai2011\CB-AA311_CB [Link entfernt]

6.5. Water Milling and electrically conductive ceramics

Water Milling_Lupamine _Report-[Link entfernt] describes the second series, from July-November 2008, involving ATR, TTMS, GT30 and GT55. Shared drums contaminated mixtures; the process involved sticking, difficult drying and cleaning. For GT30 in dry Process C with an Hc range of 95-120, the results were: Lupamine 61/160, Hexamine 144/144, Triethanolamine 163/161, acetone 112/113. For GT55 with a range of 50-65: Lupamine 68/68, Hexamine 66/66, acetone 61/62.

Spray trials yielded 29.5-42.5% fines against a target below 10%, as well as flakes and lumps of 200-600 µm. Lupamine at 0.5 wt% received a positive laboratory assessment; Hexamine and Triethanolamine required concentration optimization. The project contains an internal invention disclosure for Hexamine and a proposal to investigate the patentability of Triethanolamine.

SN312 contains a Schneider Electric work plan with a target resistivity of 20-80 ohm*cm, manufacture of TiB2/BN plates and composition adjustments. A separate program concerns electrical discharge machining of KY1615/HTN73, roughness, microstructure and bend tests. The CarCer project proposal considers adding carbon nanotubes and nanofibers to ceramics to control conductivity, fracture toughness and thermal expansion.

Documents:

D:\[Link entfernt]\_\SMBFTP\Projects\alte Projekte\MG-WA310 Water based hard metal\G4 28Apr10 19Aug10\Water Milling_Lupamine _Report-[Link entfernt]

D:\[Link entfernt]\_\SMBFTP\Projects\SN312 Platform - Electrically conductive ceramics\Start\Idea [Link entfernt]

D:\[Link entfernt]\_\SMBFTP\Projects\alte Projekte\CarCer - Carbon Nanotubes in Ceramics\draft2_proposal_CarCe.doc

6.6. KY4300: cracks, surface defects and process causes

Correspondence concerning order 111464121 dated 06.06.2012, product RPGX090700, records 625 acceptable products and 71 with cracks: 10.2% across these two groups. Photographic documents for order 111734439, batch 25228, dated 02.10.2012 show a crack and edge chip. The Plattenbruch series contains quarterly indicators for 2006-2010: the proportion of orders with at least one cracked insert at the reported points is 4.82-20.79%.

For dark spots, a materials scientist's letter dated 06.12.2016 identifies the process cause as a slurry dispersant that produces 1 mm spots. The letter instructs that products with spots on the cutting edge be rejected; the author estimated annual losses at $40 000-50 000. The production table for 02.07.2012-27.10.2015 contains 324 records, 318 orders, 6 393 scrapped units and 39 095.39 LC in standard cost under the reason Dunkle Stellen (Keramik). The table denotes the cost in LC.

The slurry-dispersant replacement plan calls for trial batch LA23/16 weighing 2 kg, using Dolapix A88 during 15.12.2016-19.01.2017, with checks of specimen density and height. Correspondence calls for a cutting test and changes to the binder and dispersant specifications and work instructions.

White areas on 38 sorted parts from order 117748824, MM1203713, have a different explanation. The materials scientist's reply of 07.11.2018 connects them with insufficient removal of the outer edge of the hot-pressed disc and considers the material itself sound. Possible conditions identified are discs that are too thin or uneven machining of the sides.

Documents:

D:\[Link entfernt]\_\SMBFTP\Manufacturing\KY4300 - KYHS10 - SP5900 - CW3020\12 10 - Risse\KY4300_Riss.docx

D:\[Link entfernt]\_\SMBFTP\Manufacturing\KY4300 - KYHS10 - SP5900 - CW3020\Plattenbruch\Plattenbruch [Link entfernt]

D:\[Link entfernt]\_\SMBFTP\Manufacturing\KY4300 - KYHS10 - SP5900 -