L'enFer,
Xillikon (and a lot of other people) know more about this than I and can probably explain it better. But see if this helps:
The OEM tops -- Alphacool, Petratech, OC, etc -- work better than the stock tops for a number of reasons. Three are more important than others, they are dynamically related, all having to do with the inlet side of the pump.
First -- bear in mind that a cooling loop is a closed loop. "Wave" type artifacts are introduced into the flow by the pump itself, the blocks, the loop geometry and the tubing, and eventually get back to the inlet side of the pump. This prevents the pump from loading liquid smoothly, and magnifies and transmits the artifacts, which return to the pump, and so on. By increasing the inlet's cross-sectional area -- creating a mini-reservoir, if you will -- the height between wave peak and trough is lessened and the effects of the artifacts are mostly eliminated.
Second -- The idea that the inlet side "sucks" liquid is not actually true. Pumps of the kind we're discussing here work best with positive pressure on the inlet. The increase in cross-sectional area is also an increase in volume -- which in turn is an increase in mass -- which translates into positive pressure.
It's intuitively clear that these things -- smoothness of the flow and positive pressure at the inlet are related.
Third -- Another intrinsically related inlet concern is flow laminarity. In this case, "laminarity" refers to the tendency for the center of a linear flow (i.e., mostly going in one direction, and moving through a tube) to move faster than the outside. Again -- the problem is largely resolved by increasing the cross sectional area and volume. The volume increase is proportional to the cube of the dimensional change, the area increase is proportional to its square, and the circumference directly proportional. The "outside" of the flow is defined by the circumference, while the center is defined by the area (static) or by volume/time (dynamic). However you look at it, a lesser portion of the flow is effected by laminarity in an aftermarket top. .
Something to remember when you're designing your loop -- The actual internal diameter of most high-flow g-1/4 fittings is actually 0.366", just a skosh less than 3/8". Using a 1/2" instead of 3/8" barb on the inlet side of an OEM top won't help you much, if at all.
Hope this helps,
BDL
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