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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.

Toyota reveals new versions of FT-1 concept at Pebble Beach [w/video]

Toyota certainly caught our attention when it unveiled the FT-1 concept at the Detroit Auto Show last January. Coming from the same people who gave us the Lexus LFA, Scion FR-S and Toyota Supra, the FT-1 concept looked striking in its bright red livery. But the Japanese automaker isn't quite done with it yet.
No, we're afraid we don't have a production announcement to share at the moment, but Toyota has revealed two new versions of the FT-1 concept that cast it in different light. Most notable is the graphite version pictured above. Replacing the bright red paintjob and two-tone red and black interior of the original concept, this second iteration - presented in the metal at McCall's Motorworks Revival in Monterey, California - goes for a more upscale and refined graphite exterior and a tan leather interior with exposed metal elements.
Both versions of the virtually road-going FT-1 concept will be playable in GT6, but at the same time Toyota also revealed (in digital form, at least) a virtual racing version of the concept called the FT-1 Vision Gran Turismo. Looking like the original concept was prepared for Japan's Super GT series, the FT-1 Vision GT is retuned for racing, with wider fenders, more extreme aero, competition-spec alloys on slicks and the like.

Toyota, Lexus expanding Takata airbag recall, re-notifying customers

Toyota is re-notifying owners and expanding its Takata airbag inflator recall for some regions. The renewed campaign covers 247,000 examples of the Toyota Corolla, Matrix, Sequoia, Tundra and Lexus SC430 that are located in southern Florida, along the Gulf Coast, Puerto Rico, Hawaii, the US Virgin Islands, Guam, Saipan and American Samoa. All of the models come from the 2001-2004 model years and have potentially faulty Takata-made inflators on the front passenger side. According to the company, testing shows the problem warrants "immediate action," and its press release says, "this action intensifies Toyota's efforts to reach customers and remedy previously recalled vehicles, and a small number of newly included vehicles."
According to Toyota, it submitted some recalled inflators to Takata for testing, and it found a high probability of rupturing in high humidity areas. The automaker said it had no reports yet of injuries or fatalities related to the problem.
This is Toyota's third inflator recall this year. In June, it called in for repair the same vehicles from the 2003-2005 model years in high-humidity areas, and it conducted a separate campaign nationwide for the parts in additional models. In April 2013, it also announced a fix campaign for 1.73-million vehicles worldwide for the same issue.