Bar and plate intercoolers have more rectangular air galleries, which allow a higher volume of compressed air to pass through the intercooler.
But because these galleries are not as aerodynamic, there is more resistance to airflow passing through the core.
A bar and plate intercooler is usually more robust and can withstand higher pressure than a tube and fin, but they are less efficient.
They are also heavier and usually have less of a pressure drop.
Bar and plate are denser cores from a build standpoint; they take longer to heat soak.
Some people see this as an advantage; the flip side is they also take much longer to cool down after heat soaking.
They do not flow air as well, making them inefficient.
They were never actually designed for automotive applications.
Some people prefer bar and plate intercoolers because they are sturdy, but they are also heavier.
Tube and fin, on the other hand, were always designed for automotive applications.
They flow air better, but they can heat soak faster, though they also cool down more quickly due to better crossflow.
In cars, tube and fin intercoolers are much more efficient.
Mishimoto even swapped their design from bar and plate to tube and fin.
Even more advanced tube and fin intercoolers are now on the market.
They are called square tube and fin and are in the middle ground between a bar and plate and original tube and fin designs.
They are more robust and lighter yet still have excellent crossflow.
Overall, tube and fin are more effective; however, they are not as robust as bar and plate intercoolers.
