Air Cooler Ultrasonic Cleaning and Repair

For a turbocharged engine to operate at full power and efficiently, it depends on the air entering the cylinders being cool and dense. The charge air cooler cools this air, which has been compressed and heated by the turbo, allowing the engine to “breathe.” Over time, oil, soot, and dirt accumulated on the air side, along with scale and marine growth residues on the water side, severely reduce the cooler’s heat transfer capacity. This situation directly leads to a reduction in engine power, an increase in fuel consumption, and causes exhaust gas temperatures to rise to dangerous levels. At İntermak, we restore your air coolers to their original performance using the most advanced method: ultrasonic cleaning.

• Assessment and Disassembly: The process begins with a detailed preliminary inspection of the air cooler upon its arrival at our workshop. The level of fouling on both the air and water sides of the cooler is visually assessed. Before cleaning, pressure testing is applied to both circuits of the cooler to identify any potential leaks or punctures and establish its current condition. Following the assessment, the side covers and other removable components are carefully disassembled to provide full access to the cooler’s core structure.
• Analysis and Component Inspection: The nature of the cooler’s fouling is analyzed to determine the most effective ultrasonic bath chemical and operating parameters (temperature, frequency). After the ultrasonic cleaning, the cooler tubes and fins are inspected in detail for erosion, corrosion, and potential damage. The condition of the side covers, gaskets, and sacrificial anodes (which protect against corrosion) is also examined to identify any parts requiring replacement.
• Repair and Assembly: At this stage, the Ultrasonic Cleaning process is performed first. The cooler is fully immersed in a giant tank filled with a special, biodegradable solution. High-frequency sound waves create millions of microscopic bubbles in the solution, and the energy released by the implosion of these bubbles on the tube surfaces dislodges even the most stubborn deposits (oil, carbon, scale) from the narrowest and most inaccessible areas, all without damaging the metal surface. After cleaning, any identified leaks are repaired using special welding or plugging methods in accordance with classification rules. Following the repair, the cooler is meticulously reassembled using new gaskets and anodes.