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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.

Mazda plans a new crossover for 2021

If Mazda is going to increase sales, it's going to need more crossovers. According to company CEO Masamichi Kogai, a new crossover that won't cannibalize sales of the CX-3, CX-5, and CX-9 is coming in 2021, to be built at the new U.S. factory Mazda is building in partnership with Toyota. The plant will be able to build 150,000 vehicles per year, and that full capacity will be reserved for the new CUV. With 112,235 units sold, Mazda's best-selling vehicle in the United States last year was, not surprisingly, the CX-5. With that in mind, it seems a safe bet that the new crossover will be a replacement for the discontinued CX-7 to slot above the CX-5 and below the CX-9. Kogai told Automotive News that the vehicle will be designed for America and built exclusively in the States. "We are actually going to introduce a totally new and different type of SUV," said Kogai. We don't know exactly what that means, but we hope the new model line follows Mazda's tradition of crossovers that are more fun to drive than their main competitors. Related Video:

Mazda's next-gen SkyActiv engines will drop spark plugs in favor of high compression

Homogeneous charge compression ignition, or HCCI, is the black art of internal combustion engines that aims to produce diesel-like fuel efficiency for the cost of gasoline. Although some of its competitors have developed and subsequently given up on the tech, Mazda confirmed that the next-generation of SkyActiv engines will employ HCCI technology, improving fuel economy by 30 percent and at the same time reducing exhaust emissions. According to Nikkei, a new SkyActiv family of engines is set to debut under the hood of the next-gen Mazda3 sometime in 2018 before making its way into other vehicles. In simple terms, an engine that uses HCCI burns the air/fuel mix using pressure instead of with spark plugs, just like a diesel. At 14:1, Mazda's gasoline engines already have some of the highest compression ratios out there, but a move to HCCI means cranking up the compression to 18:1. While the tech sounds relatively straightforward, using HCCI means dealing with a number of side issues. It's one of those "on paper" ideas that compounds problems when put into practice. Heat, revs, and fuel must all be carefully managed as gasoline doesn't burn the same way as diesel. Mazda is mum on details, but the automaker seems confident that the issues have been sorted. If the new engines do indeed make it to market with HCCI, Mazda will have out-engineered GM, Daimler, and Hyundai, all of which have tried and failed to develop HCCI engines in a cost-effective package. With the market moving towards electrification, it's interesting to see Mazda still focusing so heavily on traditional internal combustion gasoline engines. It's an indication of where they see the market heading for the next few years. Although the automaker has been hesitant to move forward with hybrid and electric powertrains, Nikkei also reports that Mazda will begin mass production of EVs in 2019. Related Video: