Spectra Premium charge air coolers are manufactured with a vacuum brazed all aluminum construction. The charge air cooler core is assembled from component tubes, fins and internal fins. This assembly is then vacuum brazed together forming a single piece core. The resulting structure is tremendously strong due to the reinforcement provided by the external and internal fins. After the charge air cooler is assembled and brazed, the end tanks (or manifolds) are welded on to the core.
The welding process provides a means of attachment which is as strong as the aluminum itself. The fins are designed to trip the boundary layer of the air flow over them, thus reducing the thickness of the boundary layer and enhancing heat transfer.