Stephen Van Hall
Stephen N. Van Hall, Ph.D.
Associate
Materials & Corrosion Engineering
Menlo Park

Dr. Stephen Van Hall specializes in failure analysis, fractography, mechanical testing and metallurgical engineering. He has specific experience examining mechanical properties and heat treatment of various automotive and industrial steels to yield various microstructures that target specific mechanical properties. Stephen is interested in mechanical joining techniques and the associated difficulties that arise when dealing with mixed materials.

Dr. Van Hall joined Exponent after completing his Ph.D. at the Colorado School of Mines while working with the Advanced Steel Processing and Products Research Center (ASPPRC). His thesis work focused on the development of self-piercing rivets (SPR) with improved mechanical properties to facilitate the successful joining of high-strength steel and aluminum for automotive use. The project first defined the current failure modes of the rivet before a novel heat-treatment was developed to improve the relevant mechanical properties.

He has also served as a teaching assistant for several undergraduate metallurgy courses and presented his thesis work to several conferences.

CREDENTIALS & PROFESSIONAL HONORS

  • Ph.D., Metallurgical and Materials Engineering, Colorado School of Mines, 2017
  • B.S., Ceramic and Materials Engineering, Clemson University, 2013

Publications

Van Hall SN. Novel alloys and processing methods to produce self-pierce rivets capable of joining 22MnB5 press-hardened steel and Al6111. 6th International Conference on Hot Sheet Metal Forming of High-Performance Steel (CHS2), Atlanta, GA, June 4-7, 2017.

Van Hall SN. Evaluating the performance of current self-pierce rivet technology for the joining of high strength steel and advanced aluminum alloys. Proceedings of the Manufacturing Science and Engineering Conference (MSEC), Detroit, MI, June 9-13, 2014.

Patents

United States Provisional Application No. 62/395,731; Title: Decarburized Self-Piercing Rivet, Submitted September 16, 2016.

Prior Experience

Graduate Researcher, Colorado School of Mines, 2012-2017

Supplemental Engineer, Ford Motor Company, 2014

Ceramic Engineer, Oxane Materials, 2012

Professional Affiliations

Association for Iron and Steel Technology—AIST

Project Experience

Performed a failure analysis investigation to determine the root cause of failure during self-pierce riveting of high-strength steel and aluminum alloys.

Identified heat-treatment issues with a safety critical component during vehicle manufacture and prescribed solutions to achieve the required product quality.

Additional Information

Peer Reviewer

Journal of Manufacturing Science and Engineering

CREDENTIALS & PROFESSIONAL HONORS

  • Ph.D., Metallurgical and Materials Engineering, Colorado School of Mines, 2017
  • B.S., Ceramic and Materials Engineering, Clemson University, 2013