GTRNICK

I am going to put the intercoolers in my car through an Independent test in a special wind tunnel which is also used to test heat exchangers for F1 teams, motorsport teams, the military and so on.

I would love to know what you guys think and if you feel if there should be any changes to the data I have been advised of?

I will also test against the GT2 RS coolers as a point of reference unless you think there is any better.

The points of data below is what I have been advised to go for by the company.

CAC Test Matrix
Charge Air Flows: 0.1, 0.2, 0.3 kg/sec
Charge Air Inlet Pressure: 1.5 bar (g)
Charge Air Trmperature: 150°C
Coolant Air Flow: 3, 6, 10 m/sec (High & lowest flow to be confirmed on day of test)
Air Temperature: 30°C
Points in Matrix: 9


I will also receive a heat rejection chart/graph.

Igooz

Good move!
Also, Delta P across IC is important as a measure of restriction, as well as a calculation on the heat exchanger efficiency which includes fin density/thickness/...(fpi)...
And sounds like you are doing Heat Rejection measures against air flow...some heat exchangers lose efficiency rapidly as the air flow increases due to the fpi as you get into higher airflow and aerodynamics issues...but you know all this stuff...
Please share any conclusions.

GTRNICK

Cheers Igooz. I think this is standard info they also give you. I will put up an example of a report they sent me.

GTRNICK

The Report is a few pages long with lots of different graphs and data etc but here is an example of the data sheet!


Model : Charge Cooler AAF212 in EUDC 5 Confguration
Serial No. : AAF212 - 44D
Dimensions : 440 x 585 x 42 mm
Rows : 42
Tubes : 2
Fins/Dm : 46

Cooling Air Side
Mean Air Air Inlet Out Air dP
Face Velocity Mass Density Temp Temp Static Wall

(m/s) (kg/s) (kg/m³) (°C) (°C) (Pa)

1.50 0.45 1.17 24.8 65.7 25
1.98 0.60 1.17 24.9 57.6 35
3.01 0.90 1.17 24.8 48.4 62
5.03 1.51 1.17 24.8 40.3 134
6.01 1.80 1.17 25.0 38.4 179
8.03 2.42 1.17 24.6 34.9 293
9.98 3.01 1.17 25.0 33.5 420

1.53 0.46 1.16 25.2 58.0 24
1.99 0.60 1.17 24.8 51.9 35
3.03 0.91 1.17 24.8 43.5 61
4.99 1.50 1.17 25.1 37.3 129
6.00 1.81 1.17 24.5 34.9 177
8.01 2.41 1.17 25.0 32.9 283
10.00 3.02 1.17 24.6 31.0 419

1.50 0.45 1.17 24.9 54.4 24
1.98 0.59 1.17 25.1 48.6 33
3.01 0.90 1.17 25.0 41.4 58
5.02 1.51 1.17 24.8 35.2 129
5.99 1.80 1.17 25.0 34.0 173
8.00 2.41 1.17 24.7 31.5 281
10.01 3.01 1.17 25.2 30.7 415

1.53 0.46 1.17 24.7 46.3 24
2.00 0.60 1.16 25.0 42.4 34
2.98 0.89 1.17 24.9 36.8 57
5.02 1.51 1.17 24.8 32.2 127
5.98 1.80 1.17 24.8 31.1 171
7.99 2.40 1.17 25.0 29.7 276
9.99 3.01 1.17 25.0 28.7 412

1.51 0.45 1.16 25.0 37.7 24
2.02 0.60 1.16 25.3 34.9 34
3.03 0.91 1.16 25.0 31.3 56
4.99 1.50 1.17 24.8 28.6 125
6.01 1.81 1.17 24.5 27.7 170
8.00 2.41 1.17 24.6 27.0 277
10.02 3.01 1.17 25.1 27.0 409
No Charge Air Flow
1.50 0.45 1.17 24.4 25.2 22
2.00 0.60 1.17 24.4 25.3 31
3.03 0.91 1.17 24.4 25.2 55
4.99 1.50 1.17 24.4 25.3 120
6.00 1.80 1.17 24.7 25.5 161
8.02 2.41 1.17 25.0 25.8 274
10.03 3.01 1.17 25.5 26.3 402

Kevin

Talk to Toby and ask him to test his GT2 IC's.

drvik

Thanks GTRNICK!!!

I'm looking forward to a summary of results... Would be a great opportunity for the aftermarket IC manufacturers to put their coolers up to prove their claims!

GTRNICK

That's what I thought

TB993tt

Nick, my intercoolers are nearly 40% bigger than stock, and made out of proper aerospace cores with aerospace aluminium end tanks, resultant weight 3.76kg, yours are cheaper, now you know why, they are made out of the heavier stuff

Joking apart, I have been following your attempts to get intercooler vendors to step up and agree to your testing but I'm afraid that was never going to happen, this industry is way too far gone
I'm afraid I can't be *rsed taking my car off the road to give you one of mine either, I'm not trying to sell them and I have done my testing and know that mine can support real 800PS pretty well - best of luck with the test and look forward to your results

GTRNICK

Cheers Toby

Just shows that the vendors don't have the minerals they say they have!

BTW how is the car?

Kevin

Toby, your IC's were made with the Marston cores?

TB993tt

Yeah but I think there is more than one area of "Marston" who make these cores, I think Nick's come from a different place than mine and are made out of different material and possibly/probably by a different process (fin design/location/material) including the actual design (number of rows etc).... the weight is fairly telling since mine are a LOT fatter and weigh less. Dunno, HS Marston are a £40M turnover outfit with only 300 employees but since their primary focus is heat exchangers I could imagine they have more than one set of designers and production methods....

GTRNICK

My cores are made by the motorsport department of marston but my end tanks are not hence the extra 0.1kg difference.

Plus mine also use chunky factory connections. Dimension wise mine are the same size as the OEM but they sit flush on the face where as the OEM sit in a little to slot into the plastic ducts.

Mine are larger than stock but not 40%.

Kevin

The engineering documents should be in place to show the differences between the two cores. One can see the hose connections and the weight of the endtanks. If one was to fabricate endtanks similar to Toby's IC's the results would lighten the scale.

I for one would want the maximum core to be fitted in a given space.. Again it would be interesting to see the IC's side by side. Or at least compare the engineering drawings.

eurotom

subscribed

Kevin

Nick can you secure the Marston cores that Toby has? That would be a upgraded option for your customers. I also like the hose clamp design vs the chunky factory circlip design.