Intake Manifold Design and Construction
On four- and six-cylinder engines and in fact on all multiple-cylinder forms, it is important that the piping leading from the carburetor to the cylinders be made in such a way that the various cylinders will receive their full quota of gas and that each cylinder will receive its charge at about the same point in the cycle of operations. In order to make the passages direct the bends should be as few as possible, and when curves are necessary they should be of large radius because an abrupt corner will not only impede gas flow but will tend to promote condensation of the fuel. Every precaution should be taken with four- and six-cylinder engines to insure equitable gas distribution to the valve chambers if regular action of the power plant is desired. If the gas pipe has many turns and angles it will be difficult to charge all cylinders properly. On some six-cylinder aviation engines, two carburetors are used because of trouble experienced with manifolds designed for one carburetor. Duplex carburetors are necessary to secure the best results from eight- and twelve-cylinder V engines.
The problem of intake piping is simplified to some extent on block motors where the intake passage is cored in the cylinder casting and where but one short pipe is needed to join this passage to the carburetor. If the cylinders are cast in pairs a simple pipe of T or Y form can be used with success. When the engine is of a type using individual cylinder castings, especially in the six-cylinder power plants, the proper application and installation of suitable piping is a difficult problem. The reader is referred to the various engine designs outlined to ascertain how the inlet piping has been arranged on representative aviation engines. Intake piping is constructed in two ways, the most common method being to cast the manifold of brass or aluminum. The other method, which is more costly, is to use a built-up construction of copper or brass tubing with cast metal elbows and Y pieces. One of the disadvantages advanced against the cast manifold is that blowholes may exist which produce imperfect castings and which will cause mixture troubles because the entering gas from the carburetor, which may be of proper proportions, is diluted by the excess air which leaks in through the porous casting. Another factor of some moment is that the roughness of the walls has a certain amount of friction which tends to reduce the velocity of the gases, and when projecting pieces are present, such as core wire or other points of metal, these tend to collect the drops of liquid fuel and thus promote condensation. The advantage of the built-up construction is that the walls of the tubing are very smooth, and as the castings are small it is not difficult to clean them out thoroughly before they are incorporated in the manifold. The tubing and castings are joined together by hard soldering, brazing or autogenous welding.