WORKING TEMPERATURE OF AN INTERCOOLER

[DesignByDesign]

Does anyone know what sort of temperature an intercooler rises to during operation?
There must be a formula to calculate heat gain when air is pressurised? It would be good to know what sort of temperature to expect, especially in the supply pipe from the turbo. Do fibreglass body panels need protection?

 

[patprimmer]

http://en.wikipedia.org/wiki/Combined_gas_law

Regards

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[BrianPetersen]

It will help to know what pressure ratio you are expecting across the turbo compressor.

 

[DesignByDesign]

Thanks for the posts, guys.
I am fitting a stock Subaru EJ20 STI motor into a new mid-engine car build & need to re-locate the intercooler.
I plan to swap that for an EZ36 (turbo rebuild) when I can afford it! and I need to design for that.
Perrin's EZ30 was boosted to 22psi max.
My question related to what sort of material I can use for ducting, as well as what to do with the hot air byproduct.
(in the Impreza, the air gets forced between the firewall & the transmission - must be to help cook the passengers)
Since this post, I think I have found the answer at:

http://www.gnttype.org/techarea/turbo/intercooler.html

Seems that post-turbo, the air will be in the range of 250 - 350degf. at full boost, depending on exhaust heat transfer, induction air temp etc.

 

[DigitalGT]

Depending on the application and a whole bunch of variables, the most upstream portion of the intercooler will reach temps nearly equal to compressor discharge temps. Temps can easily exceed 300° F.

FWIW, I've never seen an air to air intercooler melt anything. The possibility certainly exists though.

When refering to ducting, Are you talking about the charge piping leading to and from the IC or the deflector/ductwork used to direct ambient air over the IC?

You would be unwise to use anything other than metal charge piping. Sure plastic or composites could be used but considering the melting points, fire hazards, strength, and proximity to 1600° F turbines, it's not worth it. Aluminum or steel pipe is quite cheap, can contain more pressure (per given cross section) and is essentially impervious to heat. Plus you can bend it.

For ambient air duct work or deflectors, use whatever floats your boat so long as it's safe for its environment.
I've used sheet metal, plexiglass, fiberglass and even cardboard before (though the cardboard wasn't permanent.) My twincharging project required me to move an air to water intercooler heat exchanger to the rear of the car to make room for a front mount air to air intercooler. Not happy with the isolation it had from airflow, I layed up some fiberglass ductwork to give it good airflow at speed and utilized some 6" fans to reduce heat soak in traffic. I did the same for the front mount IC and have had no ill effects.