The working principles of an intercooler (charge air cooler) are primarily based on Thermodynamics, Heat Transfer, and Gas Laws. In a diesel truck, the intercooler cools the compressed air leaving the turbocharger before it enters the engine.
Cooling the charge air can:
- Increase oxygen available for combustion.
- Improve fuel combustion.
- Increase engine power potential.
- Reduce exhaust gas temperatures.
- Help reduce thermal stress.
- Improve fuel efficiency under appropriate operating conditions.
- Allow the turbocharger to provide higher-density air without simply increasing intake temperature.
Air to Air Intercooler
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.
Do Diesel Trucks Have Intercoolers?
Yes, most modern turbocharged diesel trucks use an intercooler, although in the heavy-duty truck industry it is more commonly called a Charge Air Cooler (CAC).
For a heavy-duty diesel truck, we would recommend a Dura-Lite™ CAC particularly when reliability and long-term operating costs are more important than simply choosing the cheapest replacement.
Dura-Lite's Evolution® CAC uses a Proprietary High-Temperature Silicone Grommet Tube-to-Header Sealing System rather than conventional brazed tube-to-header joints. Dura-Lite has specifically designed its Evolution charge air cooler to address cracking and leakage associated with heat stress and thermal cycling.
A heavy-duty Intercooler doesn't operate at one temperature. The aluminum core repeatedly heats and cools as the truck accelerates, climbs hills, idles, and operates under different loads.
Dura-Lite's Evolution design is intended to resist heat-stress fractures, which can otherwise result in boost leaks and loss of performance.
The job of an intercooler isn't simply to survive pressure; it needs to efficiently transfer heat from the compressed charge air to the outside air.
Dura-Lite’s Evolution CAC is engineered for high thermal efficiency, with the objective of lowering charge-air temperature and increasing air density.
Most Evolution CACs carry a non-prorated 7 Year/ 1,000,000 Mile Warranty, and warranty labor is also covered for qualifying Evolution CAC installations for the first two years.
What Does An Intercooler Do For A Truck
An intercooler on a truck doesn't simply exist to make the intake air "cooler." Its real purpose is to increase charge air density and improve the engine's overall operating conditions.
For a heavy-duty diesel engine, the ideal charge air cooler needs to achieve three things simultaneously:
- Maximum Heat Transfer:
Remove as much heat as possible from the compressed air.
- Minimum Pressure Drop:
Avoid making the turbocharger work unnecessarily hard to force air through the CAC.
- Structural Integrity:
Withstand high boost pressures, vibration, thermal cycling and the harsh operating environment of a heavy-duty truck.
This is why the design of the tubes, fins, headers, tanks, materials and airflow paths is critical, and the reason you should chose a Dura-Lite Evolution for a replacement truck Intercooler.
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