<p>A charged air cooler is one of the most important components applied in a turbocharger system. This study aimed to investigate the damage characteristics of a charged air cooler using a broken intercooler as the research object. Various experiments were conducted to analyze the microstructure at the damage point. The fluid–structure coupling interaction simulation was performed to determine the temperature field of the equipment under the given operating conditions. Finally, the reason for the damage was proposed based on the experimental findings. The results showed that the welding process and high temperatures led to the growth of the precipitated phase during equipment manufacturing and operation, reducing material strength. In addition, the silicon and oxygen elements within the material contributed to crack initiation and damage. The findings of this study provide theoretical guidance for improving the design of the equipment.</p>