A-A intercoolers should net better than 50% efficiency. Anybody who is settling for 50% is simply cutting themselves short of what their system could do or ignoring system problems. Below is some data of a recent Z06 that we did. Target horsepower was 600 to the wheels

This is from a 2003 Z06 with a P1 Supercharger, duel front intercoolers (ATI kit). Power to the ground was 602 at 11.5 psi of boost, 9:1 compression.

Ambient Temperature: 73 deg F
Inlet Temperature: 120 deg F
Supercharger Adiabadic Eff: 70%
Boost: 11.5 psi

If you crunch the numbers (or use your $400 simulator) that comes out to 64.7% for the intercooler efficiency. That is with the car standing still on the dyno and just the dyno fan. On the street it bumps up to the low 70's with better forward air flow.

Another Example

My personal car on the street.

2000 WS6 with a D1 Supercharger, single front mount. Power to the ground was 457 at 6.5 psi of boost, 9.2:1 compression (break-in run on the dyno)

Ambient Temperature: 74 deg F
Inlet Temperature: 111 deg F
Supercharger Thermal Eff: 70%
Boost: 6.5 psi

If you crunch the numbers (or use your $400 simulator) that comes out to 76% for the intercooler efficiency.

SJH, I did take a good look around at most peoples IAT numbers, and yes, most kits are near 70% at normal boost numbers. Like it or not, 50% is a low intercooler efficiency.


Also, FWIW, all calculations are done according my $34.99 book 'Supercharged, Design Testing and Installation of Supercharger Systems', my $20 used 'Fundamentals of Classical Thermodynamics'.

 

NoGo- 6.5 psi is hardly worth even worrying about intercooling so don't even use that as an example. Heck at only 6psi you could squirt water on the pipes and blower and cool the air down nicely.
And just because your present cooler can handle 6.5 psi with good efficiency does not mean it will be anywhere near that if you jump the boost up to say 15psi and add another 100' or more heat to deal with. But I'll take your other example as some good feedback.
Guys with ATI kits have seen great efficiency at 8psi and below with the small duals but it gets worse when they up the boost. Why do you think some of the guys on this board are buying big FMIC for their ATI kits?
Vortech's aftercooler does well until you spin the g-trim really fast and then it gets lousy and can't keep up very well. Some members have posted temps of 160' or higher.
I used to run no intercooler and in 85' ambients could get charge temps to 100' with water/alky and no intercooler at 8psi. Big deal. You don't build much heat at 6-7 or even 8psi. I never even had any heat issues until I pushed the G-trim into the 70,000 rpm range which is when I had to consider intercooling.
Also with 65' air, 13psi peak boost and 75' water, I saw a 118' peak IAT with my homemade intercooler. Maybe not perfect efficiency but plenty cool to stop detonation and run very good timing. That's all that matters to me.
Heck if I had just stacked another big evaporator core I could match some pretty expensive intercoolers on a shoe string budget. May even do that some day now that I see it actually works.

I'm not sure exactly what you are trying to say as far as EAPRO 3.3 goes. It's a VERY good powerful simulator and does about a million times more than a few temp and efficiency calcs out of a book( which I also have sitting around here some where).
Oh and as far as the high price of software programs and you should know this-
Words to remember- "key generators" = ( in my best monster garage announcer voice)= Freebie...nada...zilch!
Do you think I would build myself an intercooler to save cash and then run out and buy 500$ software programs? .

Ok I'm done with this subject.
Steve