Well I spent some time this week putting together my own simulation of air temperatures based on the analysis that GulfCoastMustang presented late last week. He may be the only person that cares about the blood and guts, so the rest might prefer to simply skip to the results below.
Method- I used a simple heat balance just like GCM did setting mCpdT = Q = UAdT
System assumptions were CAI diameter of 3” and length of 28”, air inlet temp of 75F and ambient engine compartment temp of 145F. Tube thickness of .12” (might be a little too thick but it doesn’t affect the results) and a thermal conductivity of 16 W/m*K for steel.
I took the relevant properties of air (thermal conductivity, viscosity, density, heat capacity, Prandlt number) and used cubic spline functions in MathCAD to interpolate values over a range from –10 to 260 F.
Natural convection is hard to figure for the engine compartment, because no one knows exactly how air moves in there. Typical h values for natural convection are around 5-6 W/m2*K however, but I assumed 25 W/m2*K just to be safe.
Calculating an overall heat transfer coefficient at 200 CFM (flow rate at 2500 RPM) gave us U=2.6 W/K, which is pretty small (I used Dittus-Boelter to get hin values for the inside of the pipe). The overall temperature rise at those conditions is about 1.6 degrees F. Now at a worst case assumption where convective heat transfer is SO robust that the wall temperature is steady at 145F, the overall temperature rise is 7 degrees F (hin, which becomes U, for the inside of the pipe is 70 W/m2*K).
If you look at the Densecharger, which is made of ABS plastic, the thermal conductivity drops to about 0.9 W/m*K and the overall heat transfer coefficient and overall temperature increase goes practically to zero.
What it all means. There is no significant temperature effect introduced by a CAI, no matter which brand you buy. Unless your filter is exposed to engine bay air, a stock airbox, steel CAI, or plastic CAI will all have approximately the same inlet temperature to the intake plenum. Thus the ONLY benefit you should expect to see from a CAI is the performance increase gained by having a smooth pipe instead of rough rubber as the conduit for inlet air.