Effects of poplar catkin contamination on automotive intercooler: Thermal performance, pressure drop, corrosion and...

The intercooler is a critical heat-exchange component in an automobile's turbocharging system, essential for maintaining engine efficiency and maximizing power output. However, its performance is often compromised during the spring-to-summer season by widespread poplar catkins (PCs). In this study, the effects of physical blockage and chemical corrosion induced by poplar catkin pollution on the intercooler's performance were investigated, employing an integrated approach that combined field sampling, experimental simulation, and multi-technique characterization. The results demonstrate that poplar catkins are readily trapped by the intercooler and accumulate on the windward side, resulting in a significant increase in pressure drop. After 100 min of operation in an environment with a poplar catkin concentration of 800 μg/m³, the pressure drop rose from 83 to 268 Pa. Additionally, the hydrolysis products of poplar catkins contain corrosive substances such as acetic acid. Corrosion experiments reveal that localized perforations were observed on the fin surfaces after 3 days of exposure to acetic acid environment, and the number and area of the perforations increasing over time. Among the evaluated mitigation strategies, 20 Pores Per Inch (PPI) filter cotton exhibits the best comprehensive performance for the interception. This filter cotton exhibits a filtration efficiency of 96.9% for poplar catkins and effectively mitigates the increase in pressure drop caused by them.