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Mazda files patents for a sequential twin-turbo setup

Mazda has a history of interesting engine technologies, from yesterday's rotary engine to tomorrow's compression ignition engine, and new patents show it still may have some internal combustion tricks up its sleeve. The one on display in these patents isn't especially new in concept, though. A sequential twin-turbocharger setup is something Mazda itself used on the third-generation RX-7. But it's something we haven't seen much of lately. It looks like it could have some possible advantages over older sequential systems, and it has some potential advantages for enthusiasts. First a quick and dirty primer for what makes a sequential twin-turbo system distinct from other twin-turbo systems. In many twin-turbo engines, there are simply two turbos that work together as one bigger turbo. They're the same size, and they spool up at the same time. With a sequential setup, at low rpm, a smaller turbocharger is spooled up first at low-rpm for quicker throttle response, and as the rpm and exhaust pressure increases, a valve opens up that allows a larger turbocharger to also spool up and provide high-rpm boost. That's basically how the Mazda design shown above functions. A big flap blocks off the larger turbocharger exhaust inlet, channeling all the exhaust to the smaller turbo. When more exhaust is available at high rpm, it looks like that flap opens up to spool up the big turbo, too. What's interesting here is that the way the turbochargers are packaged takes up less space than past systems. It looks like both turbos are contained in one unit that shares the same exhaust outlet, meaning the exhaust manifold could be kept simple and compact. In fact, the piping for compressed intake air could also be shared, reducing the amount of piping, which would further decrease the amount of materials and possible failure points. There are a number advantages of making this system smaller. The potential applications of the system are much greater, since it could fit in smaller cars with smaller engine bays. Making the system smaller also means that there won't be as much weight, which is important from both fuel economy and performance standpoints. Finally, the smaller setup likely uses fewer materials, which could make the system cheaper and thus easier to offer on a wider range of vehicles, or at least more profitable for Mazda.

Weekly Recap: Toyota, Mazda team up to 'make cars better'

Toyota and Mazda are teaming for a noble purpose: to "make cars better." That's how the two Japanese automakers termed their partnership, which was announced this week. So what does this actually mean? The companies said they will set up a joint committee to look for areas of cooperation and named safety and the environment as issues they plan to tackle. From a product perspective, it's believed that Toyota is interested in Mazda's Skyactive engine portfolio. In turn, Mazda has its eye on Toyota's fuel-cell and plug-in hybrid technology. While more specifics were not confirmed, the companies said the "agreement will go beyond the traditional framework of cooperation," and it has the potential to be a long-range partnership. "The main purpose of this initiative is to enhance the appeal of our cars," Toyota president Akio Toyoda said at the announcement. Previously, Mazda has licensed Toyota's hybrid tech and assembled compact cars for Toyota in Mexico. Akio Toyoda said these projects "triggered" the automakers to explore further collaboration. Dave Sullivan, product analysis manager for AutoPacific, said the tie-up echoes Daimler's wide-ranging work with the Renault-Nissan alliance. "This could be a well-groomed match due to each having very unique skill sets," he said. OTHER NEWS & NOTES Volvo selects South Carolina for US factory Volvo confirmed this week that it will build its first US factory in South Carolina, with construction set to begin this fall. The company first revealed plans in March, though it didn't announce a site. The plant will have initial annual production of 100,000 units, though the vehicle or vehicles to be assembled were not specified. The factory, located near Charleston, will open in 2018 and ultimately employ 4,000 people. The facility will help Volvo continue its growth strategy, which includes strengthening its presence in the US market, where it wants to sell more than 100,000 cars per year. "Building a plant in the US is a reflection of Volvo Cars' commitment to the US and the key role the US plays in our growth objectives," Lex Kerssemakers, senior vice president, Americas, said in a statement. Ford GT spied on the road The 2017 Ford GT was spotted testing around the Blue Oval's headquarters in Dearborn, MI, this week. The raw body panels were exposed, and they lacked paint or camouflage. It's the first time the GT has been captured on the street after a spring of auto show reveals.

Mazda considering a 'hyper' Mazda3 with the 250-hp 2.5-liter turbo four

Mazda boss Akira Marumoto said last year there'd be no Mazdaspeed version of the new Mazda3 because the hot hatch segment wasn't a priority for the carmaker. Then Mazda engineer Dave Coleman told Road & Track that without "an engine on the shelf that would fit properly," an MPS variant made no sense. The first reader comment on our Coleman post read, "Engine — you have it; cue up the 2.5T." Mazda might have been listening. Program manager Kota Beppu told Autocar he'd like a "hyper" Mazda3, the outlet figuring the 2.5-liter four-cylinder turbo would make the most sense for power. Autocar wrote "the project had not been officially signed off, [but] insiders suggest that is a formality." When Car and Driver queried Mazda and its sources about the report, the magazine realized "the company is seriously considering a high-performance hot hatch." What's more, "Drew Cary, senior manager for brand communications, said, 'We encourage people to ask for it, though. Our planners and executives are watching and listening to fans.'" The turbocharged 2.5-liter SkyActiv-G four-cylinder — which doesn't sell in Europe — makes 250 hp on premium gasoline and 310 pound-feet of torque in the Mazda6, CX-5 and CX-9. A next-generation SkyActiv-G is predicted on the way next year, bringing more boost and power. Even as is, we're talking a chunky lump of power to send to the front wheels, and Beppu mentioned torque steer. The new Mazda3's all-wheel drive would alleviate that bugbear. Unlike the raw, fast-twitch reflexes of the last Mazdaspeed3 from 2013, Beppu says a new model "needs to be responsible and friendly ... more friendly than a Golf GTI." And, "It should be fast." The polished looks and interior address the necessary perceptions. CD's done the math on the current 2.5-liter and predicts a five-second sprint to 60 miles per hour, which is Volkswagen Golf R and Honda Civic Type R territory, so GTI comparisons could be a case of aiming low. Imagine a 300-hp engine with a touch more torque and a six-speed manual ... If Mazda follows through with such a product, it could take two years to get the green light. However, we're told that Mazda's Los Angeles research and development center has already built a proof-of-concept to encourage and anticipate that green light.