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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 Sport sets up new shop in Neuburg

Racing fans may know Audi best for its Le Mans team that's positively dominated the endurance racing scene. But as formidable as its Le Mans program is, that's only one of the racing disciplines in which Audi competes. It also competes in the full FIA World Endurance Championship, as well as Germany's popular DTM touring car series and supports customer teams in GT racing series around the world. And now the competition division is getting a new headquarters.
Audi Sport has until now been based in an old supermarket near to the company's head offices in Ingolstadt, but is now moving into a brand new, state-of-the-art facility 12 miles to the west in nearby Neuburg. The result of some 20 years of planning and two years of construction, the complex covers 116 acres of land in Neuburg-Heinrichsheim and will house engineers, technicians and other staff who deal with the R18 E-Tron Quattro, the RS5 DTM and R8 LMS Ultra that compete the world over.
The facility was officially opened this past Saturday with participation from top Audi brass and local government officials and included demonstrations from all three of those racecars around the on-site test track. The works team has begun moving in and the customer racing department will move into its new Motorsport Competence Center in the first half of 2015.

Audi unveils A3 Sportback G-Tron with bi-fuel power, 808-mile range

By this time next year, the Audi A3 Sportback will be offered with a variety fuel-efficient powertrains ranging from diesel to the all-electric E-Tron, but perhaps the most interesting is the all-new G-Tron model, which uses Audi's innovative carbon-natural compressed natural gas called e-gas. Previously called A3 TCNG, we first heard about this technology last year, but now Audi has confirmed that this low-emission, sustainable-fuel will debut by the end of this year on the A3 Sportback G-Tron.
To create this e-gas, a plant in Werlte, Germany uses electricity to split water into hydrogen and oxygen. As hydrogen fuel cell vehicles become more popular, Audi says that this process could also be used to produce hydrogen fuel, but to create CNG, it mixes the hydrogen with carbon dioxide to create "synthetic methane." Since it is identical to the CNG available today, Audi's e-gas can be shipped and stored using the existing CNG infrastructure. Making the whole process even greener, Audi obtains the CO2 for this process from a nearby biogas plant, which would otherwise be released into the atmosphere.
Differentiated from the regular versions of the A3, the G-Tron features a pair of tanks under the rear cargo floor holding 15.43 pounds of CNG, which can power the car for almost 250 miles. What's more, the A3's conventional gasoline tank is still in place, giving the car an addition 560 miles of range. In total, that means the A3 G-Tron has a driving range of more than 800 miles. To run on both CNG and gas, Audi made changes to the car's 1.4-liter four-cylinder engine (including the turbo, cylinder head and fuel injection system) and catalytic converter.