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Crash test videos show how rust compromises safety

These recently released Swedish videos serve as a reminder that rust isn't just a cosmetic flaw, when it comes to cars. The insurance company Folksam and the homeowner organization Villaagarnas Riksforbund gathered examples of two relatively popular, but by now rusty cars, and then performed crash tests with them at the Thatcham Research facility in Britain. The results are sobering. The rustier cars chosen for the tests were first-generation Mazda6s, cars that have a reputation for early-onset rust in salty surroundings, such as the Nordic countries in Europe or the Salt Belt in the U.S. The cars in the other end of the spectrum were fifth-generation Volkswagen Golfs, which thanks to their body treatment only really start to show rust at over ten years old. But rust isn't just on the surface, it goes bone deep. While the Mazda did decently well in Euro NCAP testing as a new car, there's now a 20 percent higher risk of death in the 2003-2008 Mazda due to the degradation of its bodyshell. In the rusty car, the chassis rail separates from the floor, the footwell ruptures, the sill gives way, the seat mountings move and the dummy's head hits the B-pillar; all important failures, despite Thatcham saying the cars actually performed better in the crashes than they expected with all the rust. But still, the corroded structure isn't able to transmit loads in the way it was originally designed to do. This content is hosted by a third party. To view it, please update your privacy preferences. Manage Settings. The Golf does significantly better — despite rust flakes flying when the Golf hits the wall — as the years have only caused it to lose a single point. An important thing to remember is that the cars aren't tested in comparison to corresponding new, 2018 cars: the tests are in reference to the crashworthiness standards in place when they were new. The cars' airbags inflate like they were supposed to, but on the Mazda the dummy's head bottoms out the airbag due to the car's structure failing, meaning the airbag cannot perform as designed. Driven cautiously, an older car is still mostly fine for driving around. But tests like these remind us that it's not enough that a car runs and drives, if the body has turned into Swedish knackebrod. And if you repair the visible rust and the structure underneath remains as compromised as ever, there's an ugly truth under all the bondo. Perhaps it isn't such a bad idea to have yearly roadworthiness inspections.

Mazda expands scope of vehicles affected by Takata airbag recall to 330k

Earlier this week a Reuters report indicated that Mazda was considering a nationwide expansion of its recall for vehicles equipped with Takata airbag inflators. The company has now confirmed said expansion, with the vehicle count jumping from 86,770 to 330,000 affected in the US. As before, the affected vehicles are Mazda6 and RX-8 cars from the 2004 to 2008 model years. Mazda reports that Takata has tested a "large number of inflators removed from Mazda vehicles" and not found any to be "non-compliant" as of yet. With that said, the company also reports in its statement that one 2005 Mazda6, located in Florida, has been identified as having had an "abnormal" deployment of the driver's side airbag. For what it's worth, though the company's statement references the Takata inflator issue as a proper recall, it is calling its own program of notification a "Safety Improvement Campaign" for the moment. Find the full, if brief, Mazda press release in the form below. UPDATED MAZDA STATEMENT REGARDING TAKATA AIRBAGS Dec 11, 2014 WASHINGTON, DC (December 11, 2014) – In addition to the actions announced on December 4, 2014, as discussed in a separate document, Mazda today announced the following steps in the Takata recall: Mazda will institute a nationwide Safety Improvement Campaign of 2004-2008 model-year Mazda6 and RX-8 models equipped with certain Takata airbag inflators. The nationwide Safety Improvement Campaign will cover the driver's-side airbag inflator, as Mazda has not made a safety defect determination at this time. This action will support us to gather additional parts for examination and to promote customer satisfaction and safety. There are approximately 330,000 vehicles included in this Safety Improvement Campaign in the United States So far, Takata has tested a large number of inflators removed from Mazda vehicles, and NONE have been found to be non-compliant at this time One vehicle – a 2005 Mazda6 located in Florida – has been identified as having experienced an abnormal driver's-side airbag deployment. Mazda has worked closely with NHTSA on this situation Mazda will participate in the independent, industry-wide joint testing program for Takata airbag inflators For history, on December 4, 2014, Mazda announced: It would expand the area of the high-temperature, high-humidity region recall to include the Gulf Coast states.

Mazda patents show rotary engine for range-extended EV

Two years ago, Mazda introduced a fascinating range-extended electric car called the Mazda2 RE Range-Extender. It took an electric Mazda2, and dropped in an itty-bitty 330cc rotary engine. It wasn't the rotary-powered sports car we had hoped for, but it seemed like a unique way to keep the quirky engine alive and kicking. But not long after the car's reveal, it seemed to disappear. Now the basic idea has resurfaced with a few modern updates in a couple of US patents. The first patent is pretty straightforward and describes a range-extended EV similar to the BMW i3. At the front is an electric motor driving the front wheels. At the back is an internal combustion engine that powers an electric generator. In the middle is a lithium-ion battery for storing and delivering electricity. It's the same set-up as that Mazda2. The second patent is for an engine start-and-stop system, but specifically for rotary engines. The system is designed to shut off a rotary engine when not needed, much as modern piston engines do. It also stops the rotor in a position that closes the intake port to ensure no fuel or exhaust emissions slip out through the intake tract. This is necessary since there are no valves in a rotary, and air and exhaust come through ports that are "opened" and "closed" by the rotor itself. The patent also describes the possibility of firing a spark plug after the fuel has been cut to eliminate any leftover fuel emissions. This system would theoretically improve a rotary engine's fuel economy and emissions significantly, which would be a boon as those are two of the rotary's major weaknesses. The rotary-engine patent also includes the same range-extended powertrain drawing as the first patent. It's there as a description of a possible application. And in such an application, where the rotary wouldn't have to run all the time, the system could take advantage of the rotary's inherent strengths. Weight can be kept low thanks to the engine's small dimensions, which should help in keeping the car sprightly and efficient. Rotaries are renowned for smoothness, too, so it shouldn't need too much refining and sound deadening, the latter of which adds more weight. The small size would also help with packaging, leaving more space for people, cargo, or possibly batteries. And since it has been patented, the company may be looking to bring the system to market.