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Mazda files patents for a sequential twin-turbo setup

Mazda has a history of interesting engine technologies, from yesterday's rotary engine to tomorrow's compression ignition engine, and new patents show it still may have some internal combustion tricks up its sleeve. The one on display in these patents isn't especially new in concept, though. A sequential twin-turbocharger setup is something Mazda itself used on the third-generation RX-7. But it's something we haven't seen much of lately. It looks like it could have some possible advantages over older sequential systems, and it has some potential advantages for enthusiasts. First a quick and dirty primer for what makes a sequential twin-turbo system distinct from other twin-turbo systems. In many twin-turbo engines, there are simply two turbos that work together as one bigger turbo. They're the same size, and they spool up at the same time. With a sequential setup, at low rpm, a smaller turbocharger is spooled up first at low-rpm for quicker throttle response, and as the rpm and exhaust pressure increases, a valve opens up that allows a larger turbocharger to also spool up and provide high-rpm boost. That's basically how the Mazda design shown above functions. A big flap blocks off the larger turbocharger exhaust inlet, channeling all the exhaust to the smaller turbo. When more exhaust is available at high rpm, it looks like that flap opens up to spool up the big turbo, too. What's interesting here is that the way the turbochargers are packaged takes up less space than past systems. It looks like both turbos are contained in one unit that shares the same exhaust outlet, meaning the exhaust manifold could be kept simple and compact. In fact, the piping for compressed intake air could also be shared, reducing the amount of piping, which would further decrease the amount of materials and possible failure points. There are a number advantages of making this system smaller. The potential applications of the system are much greater, since it could fit in smaller cars with smaller engine bays. Making the system smaller also means that there won't be as much weight, which is important from both fuel economy and performance standpoints. Finally, the smaller setup likely uses fewer materials, which could make the system cheaper and thus easier to offer on a wider range of vehicles, or at least more profitable for Mazda.

Mazda's Hofu plant builds its ten-millionth car

Ten million is a lot no matter which way you cut it, and no matter what you're talking about: Ten million dollars, ten million miles, ten million people... certainly ten million cars. And that's the milestone that Mazda's Hofu plant in Yamaguchi prefecture of Japan has just achieved.
The Hofu facility has been in operation since 1982, and was supplemented with a second plant on the same site ten years later. Hofu reached a million units built in 1986 and five million in 2002. But with production now at 482,100 units per year, it took less than twelve years to double that previous milestone.
The magic ten-millionth car was a new Mazda6 (known locally as the Atenza), which is built at Hofu Plant No. 2, while Hofu Plant No. 1 gears up for the new Mazda3 (aka Axela). Scroll down below for a related press release.

Mazda and Fiat finalize deal for Alfa roadster, next-gen MX-5 Miata

Although a little bit later than expected, Mazda and Fiat have signed a final agreement that will bring a next-generation MX-5 Miata to the Japanese automaker and a new roadster to Alfa Romeo. When the proposed arrangement was announced back in May, the two automakers had hoped to seal the deal last year, but it doesn't appear that the production timeline for these cars has slipped any, with both expected to start rolling off assembly lines in 2015.
Other than a shared chassis with a rear-wheel-drive layout, it sounds like the two cars are still planned to be distinct in their own ways from their styling right down to their engines. Mazda will produce both cars at a plant in Hiroshima, Japan, but it isn't clear what role each automaker will play in the cars' developmental process. The big question, of course, is what clever portmanteau name we can come up with, like Toyobaru. Mazda Romeo is the easy choice, but Alfazda might roll off the tongue a little better.
Scroll down for a brief press release from both automakers.