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Mazda's product roadmap after Skyactiv-X: diesel, rotary, hybrids, even EVs

When we first heard that Mazda had cleared the major hurdles on gasoline compression ignition, and were just tidying up the details with clear production intent, the first kneejerk thought was: That's it for Mazda's consumer diesel. In particular, the Skyactiv-D that was intended for sale in the U.S., only to be delayed for years by various regulatory roadblocks and other issues that Mazda is frustratingly (but understandably) vague on. At least, it'd die out at some point down the road once Skyactiv-X was widely available. It turns out that's not the case at all. Mazda will adopt an approach that becomes more and more electrified and diverse the closer you get to 2035. But internal combustion will play a deep and central role up to that point, and probably beyond. Before we get to what those different powertrains, diesel and electrified, will look like down the road, let's stop and think about Mazda's philosophy. It couldn't be more different from the approach of most manufacturers that are currently producing BEVs and hybrids, which are heavily incentivized by both the automakers and the government, both state and local, depending on the locality. Even with all that cash on top of the hood, the market penetration of electrified vehicles is low. Mazda's too small to lose money paying people to drive EVs and hybrids. Its risky solution (which is plucky, but has had mixed results) is to simply improve the internal combustion engine. It's achieved the best fleet average fuel economy in the U.S. already, using a range of direct-injection gas engines that are mostly naturally aspirated. A few tiny nods to electrification have been introduced, like i-eLoop regenerative braking and the Demio EV (a Japanese-market, last-generation Mazda2 with a 20kWh battery that was tested with a tiny rotary engine range extender). But the focus is on combustion, not electricity. And that focus isn't going away anytime soon. Mazda believes that pure gasoline, gasoline hybrid, and gasoline PHEV vehicles will remain the vast majority of vehicle sold through 2035. At that point, Mazda forecasts, BEV and fuel cell vehicles should make up about 15 percent of the total of Mazda's lineup. The remaining 85 percent will utilize some form of internal combustion engine. Now, that includes hybrids and even a small number of CNG/LPG cars. And these are global numbers, as well. There may be even fewer fuel cell and CNG/LPG vehicles sold here than abroad.

Tougher than steel: Wood pulp could make lighter auto parts

KYOTO, Japan — The global push among carmakers to make ever lighter vehicles is leading some auto suppliers in Japan to turn to what seems like an unlikely steel substitute — wood pulp. Japanese researchers and auto component makers say a material made from wood pulp weighs just one-fifth of steel and can be five times stronger. The material - cellulose nanofibers — could become a viable alternative to steel in the decades ahead, they say, although it faces competition from carbon-based materials, and remains a long way from being commercially viable.> Related: Jay Leno drives the Renew cannabis car — hemp you can't dent Reducing the weight of a vehicle will be critical as manufacturers move to bring electric cars into the mainstream. Batteries are an expensive but vital component, so a reduction in car weight will mean fewer batteries will be needed to power the vehicle, saving on costs. "Lightweighting is a constant issue for us," said Masanori Matsushiro, a project manager overseeing body design at Toyota. "But we also have to resolve the issue of high manufacturing costs before we see an increased use of new, lighter-weight materials in mass-volume cars."A NEW PROCESS Researchers at Kyoto University and major parts suppliers such as Denso Corp, Toyota's biggest supplier, and DaikyoNishikawa Corp, are working with plastics incorporated with cellulose nanofibers — made by breaking down wood pulp fibers into several hundredths of a micron (one thousandth of a millimeter). Cellulose nanofibers have been used in a variety of products ranging from ink to transparent displays, but their potential use in cars has been enabled by the "Kyoto Process," under which chemically treated wood fibers are kneaded into plastics while simultaneously being broken down into nanofibers, slashing the cost of production to roughly one-fifth that of other processes. "This is the lowest-cost, highest-performance application for cellulose nanofibers, and that's why we're focusing on its use in auto and aircraft parts," Kyoto University Professor Hiroaki Yano, who is leading the research, told Reuters in an interview. The university, along with auto parts suppliers, are currently developing a prototype car using cellulose nanofiber-based parts to be completed in 2020.

Mazda Skyactiv-X Review | The revolution begins with a squeeze-bang

The matte black Skyactiv-X prototype looks like a rough Mazda3, perhaps reconstructed after a bad wreck by an over-enthusiastic owner of a spot welder and lots of gaffers' tape. Ribbed ducts poke out of the dash sending two breaths of conditioned air to no one in particular. Even its revolutionary engine, the thing we're here to experience, is entombed in a massive, nondescript cover to mask its unseemly noises. It's a wild, strange way to meet a very unconventional vehicle that promises diesel-like fuel economy, a wide torque band, and an exotic method for burning less gas than ever before. It takes a few hours for Mazda's engineers to explain the fundamental principles of operation. For more detail, read our Skyactiv-X Spark Controlled Compression Ignition explainer, but here's a very brief overview. Skyactiv-X marries some traditional gasoline engine characteristics with a novel form of compression ignition called SPCCI. The key for Skyactiv-X is to use very high compression in the cylinder and an extremely lean fuel-air mixture. Squeezed right to the cusp of getting hot enough to blow up all on its own (which is very hard to predict), a squirt of extra gas and a spark interject to cross that compression-ignition threshold in a controlled and predictable manner. See the animation below: That takes a few essential components to get just right. One is a massive amount of computer processing power and some pressure sensors in the individual cylinders, because the ambient conditions change how and when these things happen. Skyactiv-X uses a clutched supercharger to pump in additional air when needed to nail the mixture precisely, and high-pressure injectors to get the low ratios of fuel to disperse properly in the chamber. And since it operates like a conventional gasoline engine sometimes, it uses valve timing to lower the very high compression ratio so it doesn't reach combustion ignition in that mode. In practice, the Skyactiv-X runs in compression ignition mode most of the time. In practical terms, that means it drives like a torquey gasoline Skyactiv engine. The torque curve is broad and flat — diesel-like in that respect. That also means it can get away with using a six-speed transmission and a lower final drive for better response. There's enough grunt and economy together that Mazda can let the engine spin faster — at 60 mph, it's running at roughly 1,000 more RPM than a similar gas engine, with greater efficiency.