2014+ Ford Fiesta ST Performance Intercooler SKU: MMINT ...€¦ · 2014+ Ford Fiesta ST...

4
REPORT AT A GLANCE ENGINEERING REPORT 2014+ Ford Fiesta ST Performance Intercooler | SKU: MMINT-FIST-14 By Steve Wiley, Mishimoto Engineer 2 3 DESIGN OBJECTIVES DESIGN AND FITMENT PERFORMANCE TESTING CONTENTS PG PG Goal: Design a direct-fit intercooler that keeps charge air temperatures and pressure drop across the core as low as possible. Results: The Mishimoto intercooler showed temperature drops of up to 26°F (14.5°C) when compared to the stock intercooler. This reduction was achieved with an overall pressure drop of less than 1 psi. Conclusion: The Mishimoto direct-fit intercooler is an excellent upgrade for Fiesta owners who want a well-balanced intercooler in terms of performance, fitment, and weight.

Transcript of 2014+ Ford Fiesta ST Performance Intercooler SKU: MMINT ...€¦ · 2014+ Ford Fiesta ST...

  • REPORT AT A GLANCE

    ENGINEERING REPORT2014+ Ford Fiesta ST Performance Intercooler | SKU: MMINT-FIST-14

    By Steve Wiley, Mishimoto Engineer

    23

    DESIGN OBJECTIVES

    DESIGN AND FITMENT

    PERFORMANCE TESTING

    CONTENTS

    PG

    PG

    • Goal: Design a direct-fi t intercooler that keeps charge air temperatures and pressure drop across the core as

    low as possible.

    • Results: The Mishimoto intercooler showed temperature drops of up to 26°F (14.5°C) when compared to the stock intercooler. This reduction was achieved with an overall pressure drop of less than 1 psi.

    • Conclusion: The Mishimoto direct-fi t intercooler is an excellent upgrade for Fiesta owners who want a well-balanced intercooler in terms of performance, fi tment, and weight.

  • DESIGN OBJECTIVES� e design requirements assigned to this project are as follows: • Design a performance intercooler that reduces charge-air temperatures when compared to the stock cooler. • Must be a direct � t with no cutting or permanent modi� cation necessary. • Intercooler should not show a signi� cant increase in pressure drop when compared to stock. • Added weight should be minimized as much as possible.

    DESIGN AND FITMENTWe began the R&D process by evaluating the stock intercooler and � nding potential room for improvement. � e stock intercooler is a relatively hollow tube-and-� n design. After evaluating the internal construction of the core, it was evident that this unit was susceptible to heat-soak. � e Mishimoto performance intercooler

    was designed to increase overall core volume and � n surface area while retaining a direct � tment.

    As shown in Figures 1 and 2, the Mishimoto intercooler increases core volume by 51% and fi n surface area by 226% when compared to stock

    � e Fiesta ST is a light, nimble vehicle, and additional weightis a concern for many owners. � e Mishimoto intercooler was tested with both bar-and-plate and tube-and-� n cores. We found that the tube-and-� n core performed as well as the bar-and-plate design while o� ering a 5.5 pound weight reduction. Giventhe weight reduction and almost identical temperature drop,a tube-and-� n core was chosen for the � nal design.

    PERFORMANCE TESTINGA completely stock 2014 Fiesta ST was used for testing. � e ambient temperature on the day of testing was approximately 60°F (15.5°C) with 20% humidity. To test the performance increases of the intercooler, a Dynapack™ dynamometer wasused to apply a constant and repeatable load on the Fiesta ST.

    To test the performance gains of the Mishimoto intercooler, the Fiesta ST was bolted to the Dynapack, and baseline pulls were made on the completely stock car. � e same test was performed with multiple Mishimoto intercoolers installed. Fourth-gear pulls showed how each core performed in terms of pressure drop, but the intercoolers did not get hot enough to show any appreciable di� erences in outlet temperatures. To compensate for this, the Fiesta was run at full load for 15 seconds at 4,000 rpm. � is allowed each core to heat-soak, which more closely simulateda track-day condition.

    From testing it was clear that the Mishimoto cores outperformed the stock intercooler in terms of temperature drop, but they showed a noticeable increase in pressure drop. In an e� ort to develop the most superior product possible, we chose to test two more cores to try to achieve the same temperature drop while decreasing pressure drop. � e results for temperature drops and pressure drops from both rounds of testing can be seen in Figures 4–6.

    FIGURE 1: � e Mishimoto intercooler core is 51% larger than stock while maintaining a factory � t.

    FIGURE 2: By reducing � n height and pitch, the surface area was increased by 226% compared to the stock core.

    FIGURE 3: A Dynapack™ dynamometer was used for vehicle testing.

    MORE INFORMATION ON THE R&D PROCESS FOR THE INTAKE CAN BE FOUND ON THE MISHIMOTO ENGINEERING BLOG.

    Engineering Report | SKU: MMINT-FIST-14 | 2014+ Ford Fiesta ST Performance Intercooler 2 Engineering Report | SKU: MMINT-FIST-14 | 2014+ Ford Fiesta ST Performance Intercooler 3

    0

    1000

    2000

    3000

    4000

    5000

    6000

    7000

    8000

    Volu

    me (

    cm^3

    )

    Intercooler Core Volume2014+ Ford Fiesta ST Stock vs. Mishimoto

    Mishimoto Intercooler

    Stock Intercooler

    0

    5000

    10000

    15000

    20000

    25000

    30000

    35000

    40000

    Fin S

    urfa

    ce A

    rea (

    cm^2

    )

    Intercooler Fin Surface Area2014+ Ford Fiesta ST Stock vs. Mishimoto

    Mishimoto Intercooler

    Stock Intercooler

  • Engineering Report | SKU: MMINT-FIST-14 | 2014+ Ford Fiesta ST Performance Intercooler 4 Engineering Report | SKU: MMINT-FIST-14 | 2014+ Ford Fiesta ST Performance Intercooler 5

    FIGURE 4: � e � rst three intercooler cores sampled showed signi� cant temperature drops when compared to stock; however, pressure drop � gures still left room for improvement.

    FIGURE 5: � e fourth core tested showed temperature drops similar to the � rst three. � e � fth core was much less dense internally and therefore showed signs of heat-soak similar to the stock core (though still slightly better).

    FIGURE 6: Pressure drop from all � ve cores compared to stock. With dense internal � ns, the � rst three cores showed a signi� cant increase in pressure loss compared to stock (black).

    � e chosen core for the Mishimoto direct-� t intercooler was test core number 4 (orange). This confi guration showed temperature drops of up to 26°F (14.5°C) compared to the stock intercooler, without showing any signs of heat-soak throughout the entire testing process. This was achieved with an increase of less than 0.4 psi (compared to stock) and an overall pressure drop of less than 1 psi.

    � ese are excellent results for a direct-� t intercooler.

    As is the case with many intercoolers, power levels did not show any appreciable gains on a completely stock tune. An intercooler’s primary function is to keep charge-air temperatures low. If the air temperature entering the engine begins to climb, the ECU will reduce power to preserve engine longevity. A performance intercooler will aid in preventing this loss of power on a completely stock tune. If an aftermarket tune is being loaded onto the vehicle, additional gains can be expected because the tuner is able to compensate for the reduction in engine air temperature.

    0.00

    0.50

    1.00

    1.50

    2.00

    2.50

    3.00

    3.50

    2500 2626 2753 2879 3005 3131 3258 3384 3510 3636 3763 3889 4015 4141 4268 4394 4520 4646 4773 4899 5025 5151 5278 5404 5530 5656 5783 5909 6035 6161 6288

    Pres

    sure

    Dro

    p (ps

    i)

    RPM

    Intercooler Pressure Drop 2014+ Ford Fiesta ST Stock vs. Mishimoto

    Stock IC

    Tube Fin

    Bar Plate 1

    Bar Plate 2

    Test Core 4

    Test Core 5

    0.00

    50.00

    100.00

    150.00

    200.00

    250.000.

    020.

    240.

    460.

    680.

    901.

    121.

    341.

    561.

    782.

    002.

    222.

    442.

    662.

    883.

    103.

    323.

    543.

    763.

    984.

    204.

    424.

    644.

    865.

    085.

    305.

    525.

    745.

    966.

    186.

    406.

    626.

    847.

    067.

    287.

    507.

    727.

    948.

    168.

    388.

    608.

    829.

    049.

    269.

    489.

    709.

    9210

    .14

    10.3

    610

    .58

    10.8

    011

    .02

    11.2

    411

    .46

    11.6

    811

    .90

    12.1

    212

    .34

    12.5

    612

    .78

    13.0

    013

    .22

    13.4

    413

    .66

    13.8

    814

    .10

    14.3

    214

    .54

    14.7

    614

    .98

    Tem

    pera

    ture

    (°F)

    Time (s)

    Intercooler Inlet/Outlet Temps 2014+ Fiesta ST Stock vs. Mishimoto

    Stock IC Inlet

    Stock Outlet

    Tube Fin Inlet

    Tube Fin Outlet

    BP1 Inlet

    BP1 Outlet

    BP2 Inlet

    BP2 Outlet

    0.00

    50.00

    100.00

    150.00

    200.00

    250.00

    0.02

    0.24

    0.46

    0.68

    0.90

    1.12

    1.34

    1.56

    1.78

    2.00

    2.22

    2.44

    2.66

    2.88

    3.10

    3.32

    3.54

    3.76

    3.98

    4.20

    4.42

    4.64

    4.86

    5.08

    5.30

    5.52

    5.74

    5.96

    6.18

    6.40

    6.62

    6.84

    7.06

    7.28

    7.50

    7.72

    7.94

    8.16

    8.38

    8.60

    8.82

    9.04

    9.26

    9.48

    9.70

    9.92

    10.1

    410

    .36

    10.5

    810

    .80

    11.0

    211

    .24

    11.4

    611

    .68

    11.9

    012

    .12

    12.3

    412

    .56

    12.7

    813

    .00

    13.2

    213

    .44

    13.6

    613

    .88

    14.1

    014

    .32

    14.5

    414

    .76

    14.9

    8

    Tem

    pera

    ture

    (°F)

    Time (s)

    Intercooler Inlet/Outlet Temps (2nd Test)2014+ Fiesta ST Stock vs. Mishimoto

    Stock IC Inlet

    Stock Outlet

    Test Core 4 Inlet

    Test Core 4 Outlet

    Test Core 5 Inlet

    Test Core 5 Outlet

  • GoMishimoto #Mishimoto

    @Mishimoto +Mishimoto

    MishimotoEngineering.Mishimoto.com

    [email protected]