Air to Water Intercooler Manufacturer | Custom Liquid-Cooled Intercooler Solutions
At CHINA SHENG, we specialize in designing and manufacturing air to Water Intercoolers that deliver superior cooling efficiency, compact structure, and long-term reliability for automotive and industrial applications. Our products are engineered using advanced aluminum plate-fin technology and precision vacuum brazing processes, ensuring optimal performance under the most demanding thermal and pressure conditions.
Whether you’re an automotive OEM, a performance tuner, or a system integrator, our custom liquid-cooled intercooler solutions provide stable, efficient heat exchange for turbocharged, supercharged, and hybrid powertrains.
What Is an Air to Water Intercooler?
An air to water intercooler(also known as a liquid-to-air intercooler) is a type of heat exchanger that cools compressed intake air using a liquid coolant instead of ambient air. The coolant—usually water or a water-glycol mixture—absorbs heat from the intake charge and transfers it to a separate heat exchanger (often a small Radiator) before being cooled again.
This system allows for more consistent cooling, faster heat transfer, and better thermal control in compact engine bays, making it an ideal choice for high-performance vehicles and tight installation environments.
How Does an Air to Water Intercooler Work?
Hot compressed air exits the turbocharger or supercharger.
The air passes through the intercooler core, where it is cooled by liquid coolant flowing through internal passages.
The cooled, denser air then enters the intake manifold for improved combustion efficiency.
The heated coolant is circulated to a front-mounted heat exchanger, where ambient air removes the heat before the cycle repeats.
This continuous loop maintains a stable intake air temperature, even under high load or repeated acceleration—eliminating performance drops caused by heat soak.
Why Choose an Air to Water Intercooler System?
Compared to a traditional air to air design, the air to water intercooler offers several key advantages:
1.Compact Installation – Ideal for modern engine compartments with limited airflow space.
2.Superior Cooling Stability – Maintains consistent performance regardless of vehicle speed or ambient temperature.
3.High Heat Transfer Efficiency – Liquid has a higher heat capacity than air, enabling faster heat absorption and dissipation.
4.Flexible Layout Design – Suitable for front, top, or rear engine configurations.
5.Improved Engine Response – Reduces turbo lag by shortening the air path and maintaining stable boost pressure.
These advantages make air to water intercoolers increasingly popular in performance cars, electric-hybrid vehicles, marine engines, and heavy-duty machinery.
CHINA SHENG Air to Water Intercooler Features
Our intercoolers are developed through rigorous design, simulation, and testing to meet the standards of global OEM customers. Each product delivers high cooling capacity, mechanical strength, and long-term durability.
Key Technical Features:
High-Efficiency Aluminum Plate-Fin Core – Optimized for maximum heat transfer area and low pressure drop.
Vacuum Brazing Furnace Technology – Ensures uniform metallurgical bonding, achieving a first-pass yield rate of 98%.
Pressure Resistance Over 4.0 MPa – Designed to handle high boost pressures in performance and industrial applications.
Corrosion-Resistant Surface Treatment – Extends product lifespan in harsh operating environments.
Custom Core Design Options – Tailored fin geometry and flow configuration to match customer’s engine and cooling system requirements.
Compact & Lightweight Construction – Achieves superior performance without sacrificing weight or installation flexibility.
Applications
CHINA SHENG's air to water intercoolers are widely used in:
Automotive – Turbocharged gasoline and diesel engines, performance tuning, and electric-hybrid systems.
Construction Machinery – Excavators, drilling rigs, and off-highway engines.
Industrial Compressors – Air compressors and power generation equipment.
Marine & Racing Applications – High-output engines requiring reliable thermal control under continuous load.
Custom OEM & ODM Intercooler Development
As a professional intercooler manufacturer, CHINA SHENG provides end-to-end development services for OEM customers:
Thermal & Structural Design Simulation
Using advanced CFD and FEA tools, our engineers optimize the core structure, fin pattern, and fluid dynamics for maximum cooling efficiency.
Prototype Manufacturing & Testing
Rapid prototype builds are validated through leak, burst, and performance tests.
Mass Production & Quality Control
Each intercooler is produced under ISO-certified processes with strict quality inspection, ensuring dimensional accuracy and thermal performance.
Technical Support & Global Supply
We provide continuous engineering support and logistics coordination to meet customer schedules and localization needs.
Air to Water Intercooler vs. Air to Air Intercooler
| Comparison | Air to Water | Air to Air |
| Cooling Medium | Liquid (water) | Ambient air |
| Heat Transfer Rate | Faster and more stable | Slower, depends on airflow |
| Installation Space | Compact and flexible | Requires large frontal area |
| Cooling Efficiency | Consistent under all conditions | Reduces at low speed |
| Maintenance | Requires coolant circulation | Lower maintenance |
For OEMs and performance specialists seeking high-density cooling in limited space, the air to water intercooler is the optimal solution.
Why Partner with CHINA SHENG
Over 16 years of experience in aluminum heat exchanger manufacturing
Advanced vacuum brazing production lines and CNC machining centers
Annual capacity exceeding 2,400 tons of heat exchanger cores
Exported to global OEMs across automotive, industrial, and construction sectors
Proven expertise in custom intercooler development and system integration
Contact Us
If you’re looking for a reliable air to water intercooler manufacturer with strong engineering capability and stable production capacity, CHINA SHENG is your trusted partner.
Email:[email protected]
Website:www.coolerchina.com
Contact us today to discuss your custom air to water intercooler project or OEM cooperation.