Intercoolers
Mezzo's microtube coolant-air intercoolers are the highest performing intercoolers in the automotive industry. Multi-pass, cross-flow, counter-flow designs provide effectiveness in the range of 98-99% in real world applications. Like Mezzo’s radiators, Mezzo’s intercoolers provide very low charge air pressure drop for a given heat load. The combination of lower charge temperature and reduced pressure drop give the customer what is needed: more power!
The benefit of a Mezzo intercooler is amplified when coupled with a high performance Mezzo intercooler radiator, and a high performance Mezzo engine radiator. By virtue of Mezzo’s heat exchanger’s unsurpassed thermal performance and low pressure drop, the resulting cooling package can be smaller and lighter than a competing air-air intercooler.

MODULAR INTERCOOLER
Mezzo takes a unique, modular approach to the architecture of its intercoolers. The result is an incredibly strong, lightweight design that allows removal of each core on a multi-core, multi-pass coolant-air intercooler. This can provide a number of benefits:

WEIGHT REDUCTION: Welding can reduce aluminum’s yield strength by up to 80%. Because Mezzo’s modular intercoolers bolt together, the aluminum used maintains its temper. Because of this, significant weight savings can be realized over welded designs. Bolted intercoolers also allow designers to use higher strength, non-weldable alloys, further increasing weight savings.

ADJUSTABLE PERFORMANCE: If the customer discovers that thermal loads are different than originally expected after initial testing, fabricating and installing new cores with different thermal performance is simple and much cheaper than building an entirely new intercooler.

REDUCED MAINTENANCE COST: In the event a core is damaged or fouled, the shell and caps of the intercooler may be reused, thus reducing maintenance and replacement costs.

EASE OF MAINTENANCE: The ability to remove the tanks and gain access to the end of the cores allows the user to flush and dry the unit much more thoroughly.


CORE IN MANIFOLD
In addition to standalone intercoolers, Mezzo can provide intercooler cores for manifold-mounted applications. A common example of this is positive-displacement blower setups that require the intercooler core to be located inside of the engine’s intake manifold.

CASE STUDY
Race Car Air/Water Intercooler System

Mezzo also designs and manufactures water-to-air intercooler systems for high-performance turbocharged engines. Normally, Mezzo designs the air-to-water intercooler and water-to-air intercooler radiator as an optimized package. The benefits of using a setup like this include packaging benefits (i.e. flexible placement of components and less restriction of charge air flow), as well as direct performance benefits.
The following comparison shows performance of a Mezzo water/air intercooler system used to replace an air/air intercooler for a winning team in a top-tier racing series. The Mezzo intercooler system matches total wet weight and charge-air pressure drop of the original air/air intercooler while providing greatly improved performance at the design conditions of 1.5 bar gauge boost, 150°C compressor exit temperature, and 35°C ambient air temperature.
For a comparison between the Mezzo microtube intercooler system and the competing air/air intercooler, see the plots below. The first plot shows the difference between intake air temperature (IAT) and ambient temperature, for several cooling air flow rates.
Clearly, if the cooling air flow rates are unchanged between the air/air intercooler and Mezzo intercooler system, the IAT can be lowered to 8.8°C above ambient instead of the original 15.5°C. That said, if the cooling air ducting is relatively unobstructed, the actual air flow rates will be notably greater, even further decreasing IAT as shown in the plot below.
The second plot shows that because the Mezzo intercooler solution has a very low cooling air pressure drop, it is theoretically possible, in an unobstructed duct, to achieve increased flow such that the charge air is dropped to merely 4°C above ambient. In Mezzo's experience with high-performance racing, it is typical to see increases on the order of 1 horsepower/°C lower of IAT. This means that the drop in IAT here could represent a power increase on the order of 5-10 HP.

Our customers require very high performance. We take great pride in designing, fabricating, and delivering products that meet your specifications on schedule and on budget. We are motivated by new, challenging projects and have both the engineering and manufacturing capabilities needed to complete the entire engineering process from concept to finished product.