Is there a boost pressure limit for intercoolers?
Intercooler’s can fail from pressure if not specifically designed to operate at that objective pressure. The failure mode is definitely not like a bomb going off, rather a failure is manifest in cracked seams, and is induced by repeatedly flexing the material of the end tanks. A panel of the cap, if large, subjected to high pressures, and in-adequately stiff, will flex in-and-out, or “oil can,” until the edges of the panel fatigue and the seams begin to crack. (Pressures up to 15 psi are usually safe for all designs) Air to air cores are normally limited to about 50 PSI. It’s not just the pressure, it’s the heat of compression that comes with these boost pressures. At 50 PSI you’re talking about entering air temperatures approaching 500 degrees F. Aluminum loses a lot of its strength at these temperatures. Going above these pressures usually mandates going to compound compressors (one compressor feeding another). In these cases it’s advisable to put an air to water cooler between compr
