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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 reports highest profits in its 94-year history

We may only be a third of the way through 2014, but for Japanese companies, March 31 marked the end of fiscal 2014, and it was a banner financial year for Mazda's global operations. The Japanese independent saw its highest global operating profits in its nearly 100-year history. Its global operating profits were up a huge 238 percent. Yes, a 238 percent increase over 2012 to 1.36 billion euros ($1.88 billion), eclipsing the brand's previous best year, 2008, by 12 percent. Net earnings, revenue and global sales volume also saw increases over the last fiscal year.
What's most impressive, though, is where Mazda saw improvement. The notoriously rough European market was rather kind to the Zoom-Zoom brand, where sales increased 25 percent to 163,000 units. That figure was bolstered by a 35-percent sales increase in Great Britain and a 20-percent jump in Germany, Europe's two largest markets. Japanese sales, meanwhile, were up a respectable 13 percent, to 244,000 units. In China, Mazda saw a 12 percent bump.
Notice we aren't talking about North American sales? That's because Mazda only saw a moderate, five-percent gain in the New World, with sales climbing to 391,000 units in the US, Canada and Mexico. This is particularly disappointing considering Mazda has launched three critically acclaimed products (CX-5, Mazda6 and most recently, Mazda3) for the North American market over the past two fiscal years. Still, it isn't a particular reason to be concerned, as IHS industry analyst Stephanie Brinley notes. "Five percent isn't terrible," Brinley told Autoblog, saying that Mazda should see a bump in 2014 as the Mazda3 picks up steam.

Mazda still really wants to bring diesels to America

Mazda's Skyactiv program has delivered much of what it promised for the brand's latest crop of products, namely great fuel economy and excellent driving dynamics. However, the Skyactiv diesel engine has yet to reach our shores. It's been promised ever since the new Mazda6 showed up here for the 2014 model year. According to a new report from Automotive News, Mazda's CEO Masamichi Kogai said that the Mazda Skyactiv D diesel powertrain is still set to make an American appearance. He told Automotive News that there is an internal timeline to get it to the States, and while he didn't reveal the timeline, he said he wants it to come here before he steps down as CEO. The powertrain is offered elsewhere, so it fits in the company's current vehicles, but the US has specific regulatory hurdles, and the engine's extra cost has to make sense from a sales and volume perspective. We doubt VW's diesel scandal helped the engine's sales pitch, either. Automotive News also reports that the next generation of Skyactiv designs and engines are also on their way and will advance and improve on the current generation's strengths. Engineers revealed to Automotive News that they expect a 30 percent improvement in efficiency and are developing an engine with the sky-high compression ratio of 18:1. This impressive ratio could be a further indication of Mazda's pursuit of homogenous charge compression ignition (HCCI) engines. Mazda has had plenty of success with its strategy of making very efficient internal-combustion engines, but there are some concerns that the company can only improve so much. The main worry comes from the company's lack of investment in hybrid and electric powertrains. Even Mazda's North American CEO Masahiro Moro expressed concern about meeting a 54.5 mpg mandate for 2025. That mandate will no longer take effect, but increasing fuel economy requirements will always be an issue. Related Video: