An air-to-air intercooler works as a heat exchanger.

Hot compressed air flows through the intercooler's internal passages while cooler ambient air flows across the outside of those passages.

Heat moves:

Hot charge air → aluminium walls → cooling fins → ambient air

The rate of heat transfer is influenced by:

• Temperature difference between the charge air and the ambient air.
• Surface area of the air-to-air intercooler.
• Air velocity.
• Turbulence.
• Thermal conductivity of the materials.
• Thickness and design of the tubes and fins.

Find out more...