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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 explains the thinking behind the MX-30's small battery pack

Mazda's first production-bound electric car, the MX-30, relies on a 35.5-kilowatt-hour lithium-ion battery pack for power. That's relatively small, but the Japanese firm argued it's exactly what the model needs to let motorists drive electric while keeping their environmental footprint in check. Christian Schultze, head of Mazda's European research and development center, told Automotive News Europe the MX-30's battery is responsibly-sized. He explained engineers took a variety of factors into account when debating kilowatt-hours, including how much energy is required to build the pack, how much electricity is needed for a full charge, and the environmental impact of replacing the battery, which Mazda expects could be necessary after the MX-30 has covered about 100,000 miles. Sticking with a smaller pack yields total CO2 emissions on par with a turbodiesel-powered Mazda3. In contrast, using a 95-kilowatt-hour battery (which is close to what Tesla's bigger models use) would have increased the MX-30's life-long CO2 output considerably by requiring more energy to build, and needing far more electricity to achieve a 100% charge. We're not quite sure that math or battery longevity assumption hold up under scrutiny. In any case, small is the direction Mazda decided to go. The trade-off is that the MX-30 (pictured) is expected to drive for about 124 miles between charges, and that figure was achieved on the hugely optimistic WLTP testing cycle; real-world mileage will be lower. That's hardly a jaw-dropping number, and the crossover doesn't qualify for the coveted long-range label, but Schultze told British magazine Autocar it's more than enough to cover the daily transportation requirements of the average European motorist, which stands at a total of 31 miles. That's significant, because Europe will be one of the MX-30's key markets. Deliveries are scheduled to begin in early 2021. Mazda hasn't announced whether it will sell the MX-30 in the United States, or if it will wait until it has a longer-range electric car to enter the segment.

Mazda files patent applications for inline-six technology, new transmission

We've known for some time that Mazda is one of the OEMs getting back on the inline-six engine bandwagon, and a report from Japan gives us a glimpse of some of the automaker's plans. Mazda has filed patent applications for both new exhaust components (depicted with an inline-six) and a new eight-speed automatic transmission.  The news comes from a blog called T's Media (fire up Google Translate), which located the new hardware in two separate fillings, one for exhaust system components and one for the new transmission.  Mazda's lineup has been exclusively powered by four-cylinder engines since the demise of the last-generation CX-9, which utilized a 3.7-liter V6 sourced from Ford. Since, Mazda has relied on turbocharging to get more power out of its SkyActiv four-pots, but changes may be coming. Prior reports have indicated that Mazda wants a new, larger engine architecture to power vehicles built on a new, larger platform. This new chassis is expected to accommodate longitudinal, rear-wheel drive powertrains, which could spawn larger crossovers and SUVs. It could also potentially underpin a new rear-wheel drive coupe, if Mazda decides to go that route.  While the inline engine itself is not news, what we're seeing here might actually be hints as to Mazda's approach to the next generation of its SkyActiv engine architecture. Mazda's exhaust patent seems to describe a scalable — perhaps even modular — setup intended to be used with inline and potentially even V-engines.  "Provided is an engine exhaust structure capable of securing exhaust efficiency while reducing the size of the engine by changing the structure of an exhaust port," a translation of the patent application's introduction says. "[T]here has been proposed a technique for collecting exhaust gas discharged from each cylinder inside a cylinder head without using a separate exhaust manifold with the aim of downsizing the engine." In other words, Mazda is looking for ways to make its future engines more compact, and the strategy detailed here is the use of an integrated exhaust manifold, similar to what other automakers (such as Honda and Ford) have utilized on their smaller-displacement turbocharged engines. The sketch above of an inline-six engine with just two exhaust ports illustrates this concept.  The eight-speed transmission, while noteworthy in its own right as Mazda currently relies on aging six-speeds, doesn't seem to offer us anything particularly game-changing.  Related Video: