I need help deciding how to create my 512sq km world

No idea. I know RVT wont really work on landacape tiles unless you set up different materials on each.

This probably has to do with your crop/cut.
You can tey to cut the tiles with an extra pixel all around, so that there is a clear overlap of 1m at all borders.
If that solves the positioning you can then just redact the mesh by eliminating the extra border.

No, I use world composition because world partition has literlaly never worked.

Assumuing its similar, then the implications have to do with the tris cound of each component.
The hogher the tris count (of lod0) the bigger the size of the component (at lod0) the harder it will be for the system to handle.

Well, for one it was just released.
On top of that unless you have a very special setup where you benefit from nanite (ei: 1 vert per cm), I don’t think there is much of a benefit from it.

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