Bhutan Intercooler housing

Aluminum intercooler housing is an important accessory for turbocharged engine, the main role is to reduce the temperature of the air after supercharging, so as to reduce the heat load of the engine, improve the efficiency of air exchange, and increase the output power of the engine.

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BhutanMotor Casing

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Product Description

Material and manufacturing process

Aluminum intercooler housing is usually made of ZL104-T1 or ZL107, with an overall wall thickness of 6mm. in order to meet the requirements of automotive lightweight design, the thickness of tube wall of the intercooler housing has been reduced by 50%, and the thickness of the inner and outer fins has been reduced by about 20%~30%.

Manufacturing Difficulties and Solutions

Due to the difficulty of casting aluminum alloy intercooler shells, the main potential risks include incomplete filling, air-holding, easy to run out and cold segregation when the pressure is high. In order to solve these problems, skeletonized design based on 3DP sand printing technology and precise calculation of crust and crystallization pressure are adopted, thus successfully solving the casting difficulties.

Performance and application

Aluminum intercooler housing between the supercharger and intake manifold reduces the heat load of the engine by lowering the air temperature, which in turn increases the power and efficiency of the engine. This design is widely used in automotive lightweight design, and its manufacturing process and performance are further optimized by 3DP sand printing technology.

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