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Since it's inception, infrared (IR) imaging technology has demonstrated nearly limitless applications in situations where surface temperature data are required. IR imaging systems offer numerous advantages over conventional surface temperature measurement techniques at the expense of a relatively large financial investment. Nevertheless, IR imaging systems are valuable engineering tools and are well suited for use in the development and evaluation of vehicular heat exchangers. The purpose of this paper is to provide background and fundamental information on IR imaging technology and to discuss it's application to heat exchanger development. Finally, several basic application examples on the use of IR imaging technology in heat exchanger development will be presented.

A review of evaporator constructions, currently used in vehicular air-conditioning applications, is presented. An examination of the drawn cup (or laminated plate) and serpentine constructions is made followed by the introduction of a new construction, the PFE™ evaporator. This is followed by a comparison of relevant geometrical parameters and various thermal/hydraulic performance characteristics. Laboratory tests indicate that the PFE evaporator provides higher cooling capacity (heat transfer rate) per installed volume, lower air-side pressure drop and comparable water (condensed) shedding characteristics with a smaller installed depth than currently produced drawn cup and serpentine evaporators.

An experimental study to determine the impact of turbocharger outlet conditions, namely boost pressure and temperature, on charge air cooler durability was conducted. A charge air cooler, locally instrumented with strain gauges and thermocouples, was installed in a vehicle and tested in a controlled wind tunnel environment at conditions which produced different amounts of peak boost pressure and turbocharger outlet temperature. Findings suggest that elevated turbocharger outlet conditions should be approached with caution and that charge air coolers for such applications should include appropriate design features.