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Water Intercooler Design & Function

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mindset

10+ Year Contributor
1,853
7
Jan 3, 2009
Brunswick, Ohio
I have an idea for an intercooler system but it could be worthless and would hate to render and manufacture it and waste my time. I need help understanding how air to water intercoolers function.

Is there water always pumping into and out of the system?
Does it alter air flow in the intercooler piping system?
If so, how?
How exactly does the water cooler, cool the air?
Is it a radiator type system?

Thank you.

*Mods feel free to move, wasn't sure where to post this*
 
I have an idea for an intercooler system but it could be worthless and would hate to render and manufacture it and waste my time. I need help understanding how air to water intercoolers function.

Is there water always pumping into and out of the system?
Does it alter air flow in the intercooler piping system?
If so, how?
How exactly does the water cooler, cool the air?
Is it a radiator type system?

Thank you.

*Mods feel free to move, wasn't sure where to post this*

Yes water is always running. Some OE fitted intercoolers have a temp activated switch to turn the pump on but that was mostly for emissions. First mod hot wire it so it runs all the time.

It doesnt alter air flow, the air is separate from water. At least that is what I think you were getting at.

The water is cooled in a radiator located at the front of the vehicle, usually it is smaller like the size of 2 trans or oil coolers mated together.

you fill the intercooler usually fire up the pump and top everything off. then the water runs constantly and as the hot air from the turbo goes in to the intercooler it is cooled by the water then then hot water is ran through the radiator and is cooled back down. In drag racing applications instead of a radiator the water is held in a big holding tank and filled with ice that way the water is close to freezing and you can get inlet air temps below ambient. Same idea on offshore race boats, they suck in sea water to cool the charged air.

The inside of a water to air intercooler looks just like the inside of a air to air intercooler.


Edit: should have consulted google before typing all that

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http://www.turbosmart.com.au/technical-articles/how-an-intercooler-works/
 
Last edited:
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