ENGINEERING

Producing large, complex, pressure tight high quality castings and other high performance products requires a team with strong engineering capabilities.  Upfront collaboration with our customers is key to ensure that their casting design is robust so that it supports being produced in high yields, at the quality and metallurgical performance levels that the market demands.

SOLIDIFICATION MODELING

One of the first tools used by Stahl’s engineers is solidification software.  Utilizing both filling and solidification routines, Stahl Engineers can better understand a castings natural thermal response when coupled with a particular gating scheme and cooling system.  By reviewing variations in casting design, gating design, and or the cooling system, a mold can be developed that meets the customers requirements and casting performance requirements, as well as production target goals.

HEAT TREAT & METALLURGY

Stahl has a world-class heat treat process.  Stahl has performed decades of extensive studies on a particular alloys response to heat treat recipe variations.  This data allows Stahl engineers to provide a specific custom heat treat recommendation to our customers to meet their specific metallurgical requirements.

In order to achieve superior mechanical properties for structures, steering, and safety critical components like control arms, steering knuckles and brake calipers, Stahl follows its best practices:

• A core focus on tilt pour permanent mold and semi-permanent mold process to promote quiescent filling and directional solidification.
• Mold designs based on Solidification modeling on the part, gating and cooling design.
• Proper Degassing controls, continuous degassing processes, and a focus on metal cleanliness.
• Robust heat treat processes utilizing Stahl-built bottom drop ovens with rapid (<10 second) quench capability.