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A custom intercooler core is an essential component of a vehicle’s turbocharged or supercharged engine. By lowering the temperature of the air entering the engine, it boosts performance and increases power output. Intercoolers consist of tubing and metal cores that are subject to wear and tear. Luckily, there are several types of intercooler cores to suit different needs and applications.
Bar-and-Plate intercooler core
This intercooler core has a system of tubes and plates. It is fitted with a series of bars that create a barrier, allowing air to flow in a straight line. The custom intercooler core bar and plate design is popular because of its durability. It can withstand the harsh conditions of high boost applications. It is also easy to clean and versatile.
Tube-and-Fin intercooler core
This intercooler core features tubes and fins. The fins create a larger surface area for heat dissipation. The custom intercooler core tube-and-fin design is lightweight, which is an added benefit for performance. It is important to intercoolers manufacturers because it is low-cost and easy to produce.
Vertical and Horizontal intercooler core
Vertical intercooler cores are designed with cooling fins and tubes mounted vertically. They have a smaller footprint and are ideal for compact vehicles or motorcycles. The air passes through the intercooler core vertically. Conversely, the tubes and cooling fins of horizontal intercooler cores are mounted horizontally. They have a larger surface area, making them more effective for heat exchange.
Oil-cooled intercooler core
The oil-cooled intercooler core uses engine oil to cool the compressed air. Because of this, the air is cooled more effectively than in other types of intercooler cores. This is because engine oil has a higher heat capacity than water or coolant. The only problem with this type of intercooler core is that it has a more complex cooling system.
Air-cooled intercooler core
The air-cooled intercooler core uses airflow to cool the compressed air. The design is simpler, and there are no additional components or fluids needed. It is also less expensive to maintain. However, the air-cooled intercooler core is less effective than the oil-cooled intercooler core.
Air-to-air intercooler core
Air-to-air intercooler cores use ambient air to cool the compressed air. They are effective at high speeds when there is sufficient airflow. The design of air-to-air intercooler cores is simple, making it easy to maintain.
Liquid intercooler core
Liquid intercooler cores use water or a liquid coolant to cool the compressed air. This makes them more effective than air-to-air intercooler cores. Liquid intercooler cores are suitable for applications where maximum cooling is required, such as racing.
Various factors are considered when choosing the right intercooler core for any given application. They are also the same parameters that are used to specify an intercooler. They include:
Core size
The core length, width, and height determine the amount of air that can be cooled and the pressure loss through the intercooler, which affects performance.
Core design
Tube and fin intercoolers are compact and cheap but have a larger surface area and a slower cooling rate than bar and plate intercoolers. Plate and shell intercoolers are also suitable for high-performance engines.
Material
Custom intercooler cores are made from aluminum, steel, and copper. Aluminum and steel are strong and corrosion-resistant. They are also suitable for welding. Copper has excellent heat transfer properties but is heavy and expensive.
Cooling capacity
This is the amount of heat removed from the air by the intercooler and is measured in watts or BTUs. Cooling capacity is affected by core size and design, airflow through the core, and temperature difference between the coolant and the air.
Pressure drop
Pressure drop is the decrease in pressure of the air passing through the intercooler core. It affects the performance of the engine by reducing the airflow and increasing the resistance. Pressure drop is affected by core size and design, as well as the shape and size of the inlet and outlet pipes.
Custom intercoolers are generally low-maintenance. However, there are some maintenance requirements that need to be adhered to in order to ensure the intercooler functions appropriately.
Inspecting the intercooler for leaks, damage, or corrosion is important. This includes checking the pipes and connections for wear and tear. If any of the mentioned components are damaged, the intercooler will be unable to maintain the proper temperature, which can lead to decreased performance and engine damage over time.
It is also important to clean the intercooler core regularly to remove dirt, debris, and oil. This can be done using a mild detergent and water or a specialized intercooler cleaning solution. The fins and tubes should be carefully cleaned, as they are delicate and can be easily damaged.
Worn-out hoses and clamps should be replaced to ensure a tight seal and prevent leaks. This is important, as even minor leaks can significantly affect the performance of the intercooler.
Power Goals
When selecting a custom intercooler core, one must consider the power goals of the engine. Higher output engines generate more heat and require a robust intercooler to manage temperatures effectively. For instance, a car with a turbocharger upgrade pushing 400hp would need an intercooler designed to handle the increased heat compared to a stock 200hp vehicle.
Space Limitations
Every engine bay has a specific size allowed for the intercooler. It is critical to measure the length, height, and width that can fit before selecting a core. Additionally, factors like clearance to other components and airflow paths should be considered.
Cooling Capacity vs. Pressure Drop
The cooling capacity of a custom intercooler core is vital when choosing it, as it shows how well it cools the air. At the same time, pressure drop is an important consideration. A core with too much pressure drop will reduce the force with which the air flows through the intake and can lead to less power being produced. Therefore, when selecting an intercooler core, it is important to consider both of these factors in order to find one that meets the specific needs of the engine.
End Tank Design
Custom intercooler core end tanks are just as important as the core itself when it comes to intercoolers. The end tanks are responsible for directing the cooled air into and out of the core. They can be designed in various ways, such as using a radius or a sharp 90-degree bend. The end tank design impacts the flow path and can affect efficiency. It's usually better to go with smooth transitions.
Material of the intercooler core
Aluminum is the most preferred material for intercooler cores due to its lightweight and excellent heat transfer properties. Steel and copper are heavier than aluminum and may not be suitable for many applications.
Fin Design
The fin design of the intercooler core is also an important factor to take into consideration when choosing a custom intercooler core. The fin design affects the core's ability to dissipate heat and the pressure drop across the core. Finned areas with larger surface areas can improve heat transfer, while tightly spaced fins can reduce airflow resistance. There are many different fin designs, such as bar and plate, tube and fin, and staggered. Each type has its own advantages and disadvantages.
Even though the intercooler core can be replaced as a DIY project, it is recommended that a trained technician replace it. This is because, to replace the intercooler core, one has to disassemble several parts of the vehicle, such as the front grill, bumper, and cooling system. However, if an aftermarket intercooler core is to be replaced as a DIY, here are some steps to follow.
Q1: How are intercoolers maintained?
A1: Custom intercoolers are maintained by regularly checking and inspecting them for any signs of wear or damage. They also ensure that the mounting hardware is intact and that the intercooler is securely mounted. They clean the intercooler during regular engine maintenance, as this removes accumulated dirt, oil, and debris that may affect its performance. Users can also use a soft brush and rinse it with water. They inspect the hoses and pipes of the intercooler to ensure they are free from cracks, leaks, or damage. They also replace damaged hoses to maintain optimal performance. They check the intercooler for any dents or damage that may restrict airflow and address them.
Q2: What are the common intercooler problems?
A2: Some problems include intercooler leaks, pressure drops, and oil contamination. Intercooler leaks occur due to wear and tear or damage to the intercooler, resulting in a decrease in charge air pressure, affecting engine performance. Oil contamination occurs when there is oil leakage from the engine or turbocharger, resulting in reduced efficiency.
Q3: What are the benefits of having an intercooler?
A3: Intercoolers have several benefits, such as improving engine performance, increasing power output, and enhancing engine reliability. By cooling the air that enters the engine, the intercooler increases the density of the charge air, resulting in more air entering the engine. The increased air results in a more effective combustion process, which increases engine power output. The intercooler aids in cooling the air charged by the turbocharger or supercharger before it enters the engine. This results in lower temperature levels, which helps the engine run smoothly and efficiently. The intercooler also helps the engine to work under less stress by maintaining optimal temperature levels. This increases the lifespan of the engine.
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