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The tricky business of octane, power, and MPG

Given tepid green-car sales numbers this year, consumers in the US aren't making the transition away from internal combustion engines too quickly. Regulations are still mandating cleaner emissions, though. In addition to downsizing and turbocharging, there's growing consideration about moving to higher-octane fuel to improve overall efficiency. In a new report, engineers at FCA, Ford and General Motors Powertrain are showing that it could work, too. The major advantage to higher-octane fuel is that it supports higher compression ratios. That in turn can lead to more power from burning the same amount of gas. "Higher ethanol content is one available option for increasing the octane ratings of gasoline and would provide additional engine efficiency benefits for part and full load operation," the researchers write in the study's abstract. The authors even think it could be possible to update some modern vehicles' engine calibration to be optimized for the better gas. While the benefits are there, we still have a long way to go before higher-octane fuel becomes a national standard. According to Green Car Congress, 87 percent of the gas sold in the US is regular grade 87-octane. Meanwhile, premium 91-93 octane makes up just 10 percent. The various grades of fuel illuminate even more annoyances with the current system. For example, Ford generally recommends 93-octane for EcoBoost engines, and the power outputs that the company publishes are based on using it. However according to Green Car Reports, such premium gas is very difficult to find in some regions of the US, especially along the West Coast. The powertrains still run on lesser grades but with lower power output. The researchers' discussion of possibly increasing ethanol in gas also comes during a heated debate on the substance. The current administration is pushing for less of the corn-based fuel in the coming years. Although, several presidential hopefuls might be favor of reversing that course.

Ford will add lots of carbon fiber to new vehicles

With BMW receiving a bunch of positive press for its usage of carbon fiber to build its i3 and i8 plug-in vehicles, Ford is jumping into that game as well. The US automaker has reached a manufacturing agreement with Dow Chemical to speed up the use of that material in Blue Oval vehicles. Carbon fiber usage will cut weight from Ford's new products, boosting fuel efficiency as a result. Ford will work with DowAksa, a 50/50 joint venture between Dow Chemical and Turkey-based Aksa Akrilik Kimya Sanayii A.S, on a manufacturing partnership. The goal is to speed up technology research to make it cheaper to make cars and trucks with carbon fiber materials. Ford's light-weighting efforts received a boost of sorts this week when its aluminum-body 2015 F-150 was awarded a five-star Overall Vehicle Score in the National Highway Traffic Safety Administration's testing, making this year's version the safest to date. The new body construction cut 700 pounds from the truck's curb weight. Take a look at Ford's press release about DowAksa below. FORD, DOWAKSA TO JOINTLY DEVELOP CARBON FIBER FOR HIGH-VOLUME AUTOMOTIVE LIGHT-WEIGHTING APPLICATIONS Ford and DowAksa formalize agreement to advance the adoption of cost-effective carbon fiber components through technology validation and proof of concept to reduce vehicle weight and increase fuel efficiency without sacrificing strength Agreement provides pathway for a high-volume manufacturing partnership New joint development agreement accelerates joint research announced in January in partnership under new U.S. composites manufacturing institute Ford and DowAksa today signed a joint development agreement (JDA) to formally advance research on cost-effective, high-volume manufacturing of automotive-grade carbon fiber, a material poised to play a significant role in the drive to make vehicles lighter for greater fuel efficiency, performance and capability. The agreement, between Ford Motor Company, Ford Global Technologies and DowAksa – a 50/50 joint venture between The Dow Chemical Company and Aksa Akrilik Kimya Sanayii A.S – will combine DowAksa's feedstock capacity, carbon fiber conversion and downstream intermediates production capabilities with Ford's expertise in design, engineering and high-volume manufacturing. The goal is to produce materials that make cost-effective carbon fiber composite parts that are much lighter than steel but meet automotive strength requirements.

Ford to build next F-150, outgoing model concurrently?

Ford is rumored to be considering concurrent production for old and new F-150 models in a bid to minimize supply chain disruptions and inventory. Automotive News is reporting that the Blue Oval will build both the current F-150 and its replacement, which we showed you testing just last month, side by side for about half a year before switching over entirely to next-generation production.
As IHS Automotive analyst Mike Jackson told AN, "In order to ramp up, you have to retool...and that means you have to take capacity offline." Building both models alongside could allow Ford to cope with the still strong demand for the current F-150, while populating dealer supplies and working out supply chain kinks for the new model before making a full-time switch.
A loss of capacity when demand is so strong, even for a short period, could spell bad news for Ford, which nets an estimated 90 percent of its global profit on pickups and large SUVs. As AN states, Ford produces the F-150 in both Kansas City, Missouri and Dearborn, Michigan, which allows it to maintain some degree of flexibility in production. The new F-150 is expected to arrive at the 2014 North American International Auto Show as a 2015 model, with a design inspired by the Atlas Concept first shown at the Detroit Auto Show last January.