Intercooler design is a delicate balance of pressure and flow. Too much flow means that the charge air does not stay in the core long enough to transfer heat. Too little flow, and too much pressure, means all the work your turbo or supercharger has been doing is wasted on forcing the air through the cooler instead of into the cylinders. Heat transfer happens rapidly inside an intercooler, so it's difficult to make an intercooler core that has good flow. That doesn't mean we could use just any core in our 2011-2017 6.7L Powerstroke intercooler. Like all our products, this intercooler needed to be extensively tested before it finds its way into our customers' trucks.
In our last post, we looked at our prototype with its 3D-printed end tanks and aluminum bar core. In this post, we'll test real cores with production end tanks to get the most accurate results.