Turbochargers 101: Understanding the Importance and Function of Intercoolers and Piping
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The term “turbocharged” has become ubiquitous in the automotive world over the years, and for good reason. Nothing delivers a more satisfying driving experience, in terms of sheer acceleration, than a vehicle that is equipped with a turbocharger.
In basic terms, a turbocharger is a device that compresses and forces air into the engine combustion chamber, creating a more potent combustion process that yields more power, and thus, more acceleration.
However, the turbocharging process generates a substantial amount of heat, which tends to lower the air density and pressure at the charge air temperature (CAT). This is where intercoolers and piping come in.
In this article, we’ll take a deep dive into the world of intercoolers and piping, discussing their importance, function, and how they contribute to the turbocharging process.
Intercoolers – The Cooling Factor
As mentioned earlier, turbocharging generates heat, and with increased heat comes reduced air density and pressure. Intercoolers are designed to combat this problem by reducing the temperature of the air that passes through the turbocharger before entering the combustion chamber.
Intercoolers are often referred to as charge air coolers because they cool the charge air (air that enters the engine) coming from the turbocharger. They work by using a coolant that is connected to the turbocharger, where the coolant is responsible for cooling the hot air before it reaches the combustion chamber in the engine.
When you have a cooler air intake entering the engine, you essentially have more oxygen entering the combustion chamber, which results in better combustion and more power. The efficiency of intercoolers has a direct impact on the vehicle’s horsepower and torque output, and therefore, they are critical components in the turbocharging process.
Types of Intercoolers
There are two main types of intercoolers: air-to-air intercoolers and air-to-water intercoolers.
Air-to-Air Intercoolers: As the name suggests, air-to-air intercoolers utilize air as the cooling medium. These intercoolers use a heat exchanger core, which transfers the heat from the hot air to the cool air, thereby reducing the charge air temperature. They are the most common type of intercoolers in use today because they are highly effective and relatively easy to install.
Air-to-Water Intercoolers: These intercoolers use a liquid, typically water or a water-glycol mixture, as the cooling medium. These intercoolers operate by passing the hot air through a heat exchanger before transferring the heat to the liquid coolant. This coolant then circulates through a heat exchanger where air is used to cool the liquid before it returns to the charge cooler. Air-to-water intercoolers are highly efficient, but they are more complicated and expensive to install than air-to-air intercoolers.
Intercooler Piping
Intercooler piping is essentially a system of hoses or pipes that connect the turbocharger to the intercooler and the intercooler to the engine. The piping system is responsible for transporting the compressed and cooled air from the turbocharger to the intercooler, and then from the intercooler to the engine.
Piping systems are often overlooked when it comes to turbocharging because they do not directly contribute to power output. However, intercooler piping systems can have a substantial impact on the overall performance and efficiency of the turbocharger.
Types of Piping
There are two main types of intercooler piping: aluminum and silicone.
Aluminum Piping: Aluminum piping is the most common type of intercooler piping used in the automotive industry. It is preferred because it is lightweight, durable, and can withstand high temperatures.
Silicone Piping: Silicone piping is another option for intercooler piping. It is typically used in high-performance applications because it can handle higher boost pressures without collapsing. Silicone piping is also flexible, which makes it easier to install than aluminum piping.
FAQs
Q: Can you install aftermarket intercoolers and piping on any car?
A: Yes, aftermarket intercoolers and piping can be installed on almost any car. However, it is important to ensure that the intercooler and piping are compatible with your specific make and model before installing them.
Q: How much horsepower can I expect to gain by installing a larger intercooler?
A: The horsepower gains will vary depending on the make and model of your vehicle. However, it is safe to assume that installing a larger intercooler will increase horsepower and improve performance. The exact amount of horsepower gains will depend on multiple factors, such as the size of the intercooler, the quality of the intercooler, and the tune of the vehicle.
Q: Can intercoolers and piping affect fuel economy?
A: Yes, intercoolers and piping can affect fuel economy, depending on the efficiency of the system. If the intercooler and piping are highly efficient, the engine will burn fuel more efficiently and thus increase fuel economy. However, if the intercooler and piping are inefficient, the engine will consume more fuel to maintain the desired level of boost pressure, leading to a decrease in fuel economy.