The main goal for any aluminium billet producer is to achieve high quality billets at a low operating cost with minimal impact to the environment. The Airsol Veil~R and Air-glide~R mold technologies provide an effective tool to achieve these goals using a unique mold design, a PLC-controlled air feeding system, and an optimized distribution launder design. Gautschi~R of Switzerland recently purchased all relevant patents and trademark rights from Hydro Aluminium concerning the Airsol Veil and Airglide mold technologies (Figure 1). Gautschi, a part of MAERZ-Gautschi, covers the whole range of melting, casting, and heat treatment equipment for the primary and secondary aluminium industry. VAW, the former German aluminum company which is now part of the HYDRO Group, has a long history of designing molds and mold systems. As a major leap in technology, they first introduced the Airsol Veil mold in 1986. The name refers to the air veil, which forms an air cushion between the liquid aluminum and the inner mold wall, thereby reducing the heat flow between the two surfaces. Initially, the air pressure to create the air cushion was conventionally controlled. However, this system of a conventionally controlled air cushion proved not to be practical in a modern casthouse. This led to the setup of a cooperation for the joint development of a new mold control system in 1991 utilizing VAW's vast knowledge of casting aluminum billets and Gautschi's experience in automation and control systems.
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