Charge Air Coolers

A charge air cooler (CAC), also known as an intercooler, is a heat exchanger used in internal combustion engines to cool the compressed intake air before it enters the combustion chamber. Its purpose is to increase the density of the intake air, resulting in improved engine performance and efficiency.

In turbocharged or supercharged engines, the air is compressed by a turbocharger or supercharger before entering the intake manifold. The compression process increases the temperature of the air, reducing its density. Hotter and less dense air contains less oxygen, which can limit the engine’s power output.

Charge Air Coolers Operation

To counteract this, a charge air cooler is installed between the turbocharger or supercharger outlet and the intake manifold. It consists of a series of tubes or passages through which the compressed air flows. The charge air cooler is typically located in the front of the vehicle. This allows it to receive cool airflow, such as from the vehicle’s radiator.

As the hot compressed air passes through, it transfers heat to the cooler ambient air flowing through the cooler’s fins or tubes. This cooling process reduces the temperature of the compressed air, increasing its density and therefore the amount of oxygen available for combustion.

The cooler, denser air improves the engine’s efficiency and performance by allowing more fuel to be burned, resulting in increased power output and reduced exhaust emissions. Additionally, cooler intake air helps prevent engine knocking, which can occur when the air-fuel mixture ignites prematurely due to high temperatures and pressures.

Common Use

Charge air coolers are commonly used in diesel engines, as well as gasoline engines in high-performance vehicles. They play a crucial role in optimizing the engine’s power, efficiency, and overall performance by ensuring that the intake air remains cool and dense. Finally, contact us today for more information about available charge air coolers!