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Researchers halfway to cutting carbon fiber costs by 90%

Carbon fiber has been utilized for decades to build racecars, as a means to cut weight while maintaining strength. But until recently, the space-age material has been largely absent from the street on anything but supercars because of the expense to use it. Recently, BMW signaled a major shift in that trend when it starting using carbon fiber reinforced plastic panels on the i3 and i8. This relatively small scale start might be just the beginning; the German company believes that a breakthrough to inexpensively manufacture the lightweight stuff is just on the horizon.
MAI Carbon Cluster Management GmbH counts BMW, Audi, Airbus, the German government and many other organizations as supporters, and it's researching how to make carbon fiber cheaper to produce, according to Automotive News Europe. The company thinks it can reduce costs by 90 percent in the near future. "We've certainly reached a halfway point on our cost-cutting target for suitable carbon-fiber parts," said project head Klaus Drechsler to Automotive News Europe.
Unfortunately, it isn't entirely clear just what MAI Carbon is doing to make such a huge leap possible. However, a recent post on the company's website talks about a new form a carbon fiber using a thermoplastic matrix that could be cured in less than three minutes. That's compared to about 90 minutes in the traditional process with an autoclave.

Audi kills off its 420-hp four-cylinder engine project

Audi's supercar-slapping, fire-breathing four-cylinder concept engine will remain just that, with Autoblog confirming that it has been internally killed off. Speaking at the launch of the TT RS, the engineering boss of Audi's Quattro GmbH division, Stephan Reil, said the Volkswagen Group had stopped all development of the 420-horsepower, 2.0-liter four it showed in the 2014 TT Quattro Sport Concept car (above). Despite previous assurances that Quattro had roles for both the EA888-based engine and Audi's wildly charismatic 2.5-liter, five-cylinder motor, post-Dieselgate reality has killed the smaller engine. "The 400-horsepower EA888 engine is dead," Reil said. The EA888 engine was conceived and developed by the same man behind AMG's powerhouse 2.0-liter four. Friedrich Eichler left AMG to become the Volkswagen Group's gasoline engine development go-to guy, and he was confident the 420-hp engine could be turned into a production car quickly, as was then-Audi development boss, Ulrich Hackenberg. It was even suggested that because the EA888 engine family bolted straight into the Volkswagen Group's ubiquitous MQB small-car architecture, the little powerhouse could be cheaply and quickly dropped into any of the company's cars that needed an image boost. Since then, Quattro has elevated the five-cylinder motor, switching it to an all-alloy block with a magnesium oil pan to cut down its weight while boosting its power and torque levels. Where the four-cylinder engine was shown with 420 hp and 332 lb-ft of torque, the production version of the TT RS's new five-cylinder engine totes 400 hp and 354 pound-feet of torque. The smaller engine's proponents claimed a 0-62 mph acceleration figure of just 3.7 seconds for the concept TT that carried it, and it might not be a coincidence that the all-new TT RS claims exactly the same figure. The 2.0-liter motor had a torque peak that arrived at 2,400 rpm and began to taper off at 6,300 rpm, while its power apexed at 6,700 rpm, thanks in part to a turbocharger that could feed it up to 1.8 bar of air. Flip to the TT RS' data and you're looking at more torque at lower revs and a touch less power, but at higher revs. That's not a lot of wriggle room for the concept engine to operate, especially when the perceived value of the five-cylinder engine is higher than the four, and the four's development and production costs would be higher than the five's.

VW may make Bentley a subsidiary of Audi

FRANKFURT — Volkswagen plans to make British luxury carmaker Bentley a subsidiary of its Audi division as it seeks economies of scale among its top-end brands, German trade publication Automobilwoche reported. Bentley, for now overseen by the head of VW's Porsche business, Oliver Blume, will from next year be part of Audi, where VW group Chief Executive Herbert Diess believes it has more potential, Automobilwoche cited company sources as saying. Synergies could include using Audi technology for a new Bentley SUV, it added. Volkswagen, which declined to comment on the report, is reviewing the future of its high-performance brands Lamborghini, Bugatti and Ducati motorcycles as part of broader quest for more economies of scale as it shifts to mass producing electric cars. Sources familiar with the matter told Reuters this month that Volkswagen was working on plans to prepare Lamborghini for a stock market listing. Related Video: Audi Bentley Volkswagen