Frequently, we have people ask us what the pressure drop through a specific intercooler may be, what it’s cooling effectiveness may be, (that is what will be the temperature of the air be before it enters the engine), and will that reduction in air temperature offset the loss in pressure caused by the intercooler.
It would be difficult to design an intercooler system which would yeild no increase in power, however it is possible. Indeed, if the intercooler is improperly sized, the pressure drop will be too high and the cooling effectiveness too low, the net result will be very little or no increase in air density and/or no gain in power.
In order for this to happen, the intercooler's pressure drop must be of a fairly high magnitude, which is 2 psig (.318 bar) or more, and the intercooler would have to be undersized. With that said, the face area is too small and cooling effectiveness too low and would be hard to design an intercooler system that would cause no increase in power, however it is possible.
At Turbonetics, our engineering team stands ready to help design a specific intercooler for your application and needs. The link below will provide out team with the information required to design an intercooler specific to your needs. Click on the link below to put our experienced team to work for you.