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Stahl has tremendous casting capacity with a number of the largest machines in the industry, and rotaries for high volumes.

A HIGH VOLUME FOUNDRY

Stahl Specialty Casting is a vertically integrated operation featuring core making, a world-class heat treat, full CNC machining capability. Quality is integral to the entire process, as is the ability to X-ray real-time with automatic defect recognition, and full APQP quality inspection. Preferred volumes range from 1,000 to 1 million parts per year, and in the size range of 2 pounds (0.91kg) to 400 pounds (181kg).

Since our beginning in 1946, Glenn Stahl pioneered the development of the aluminum tilt pour permanent mold process, producing the highest quality aluminum castings for light-weighting, large truck engines, pressure-tight pumps, and industrial applications.

Depending on geometry, Stahl engineers will determine the best process for your product – gravity tilt pour, static pour, semi-permanent and permanent mold.

The STAHL Tilt-Pour Permanent Mold Process

Features of the STAHL Tilt Pour Permanent Mold Casting Process

  • The mold is closed with the parting line in a horizontal position.
  • The pour cup is filled and the mold is rotated 90 degrees.
  • The cavity is filled in a tranquil manner

The Benefits of the Tilt Pour Permanent Mold Casting Process

  • Cleaner metal through skimming design at pour cup
  • Controlled rate of metal entry minimizes turbulence
  • Controlled flow allowing for improved heat management
  • Improved ability to drive directional solidification
  • Well-represented in solidification models

RESULTS

  • Superior Mechanical Performance
  • Superior Pressure Tightness

The STAHL Static-Pour Permanent Mold Process

Stahl Specialty uses its decades of experience in producing high quality aluminum castings to select the optimal process to produce your product.  We developed the tilt process that was described above.  Another is the static pour process, which offers two main advantages:

  • Preferred solidification direction based on various part geometry.
  • The ability to cast more complex shapes.

Static Pour Process

CORE MAKING

Stahl specializes in complex castings, many of which are semi-permanent mold, meaning that there is a sand core that provides a hollow region within the component.  There are many purposes for cores, yet there are also many challenges to produce high yield cast products.  Stahl understands the challenges which include attention to the details that include managing wall thicknesses, including allowable core shift; managing outgas of core materials; surface finish; and maintaining a pressure-tight product.

 

Equipment

 

Stahl has significant in-house capacity and a fleet of machines to produce high volumes of small or very large cores. Capabilities include Hot cured (Shell) and Cold cured (SO2) and flexibility in grain sizes and resins.

Stahl’s castings are used on diesel engines that carry a million mile life expectancy before an overhaul.  The loads are extreme, and Stahl has a proven track record in producing highly cored, pressure-tight and lightweight engine products.

 

A great example of a structural and pressure-tight aluminum casting is this cover for a 5.0L diesel engine for a prominent new pickup truck.  This cover incorporates six complex sand cores to create oil, coolant, and water passageways.  The ability to produce this casting provides confidence to the leading edge engine designers.

30 Inch X 28 Inch X 9 Inch

 

 

Stahl has the largest fleet of large 48 x 60 machines, and rotaries for high volumes. Examples of large permanent mold castings are found on 15L engines for commercial trucks – front covers, oil pans and pressure-tight fuel pump housings.

Copyright 2016 Stahl Specialty Company, 111 East Pacific Street
Kingsville, MO 64061-0006 | All Rights Reserved

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Stahl Specialty Company