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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.

Asian automakers still reluctant to use more aluminum

There's a logical progression of technology in the auto industry. We've seen it with things like carbon-ceramic brakes, which use to be the sole domain of six-figure sports cars, where they often cost as much as an entry level Toyota Corolla. Now, you can get them on a BMW M3 (they're still pricey, at $8,150). Who knows, maybe in the next four a five years, they'll be available on something like a muscle car or hot hatchback. Aluminum has had a similar progression, although it's further along, moving from the realm of Audi and Jaguar luxury sedans to Ford's most important product, the F-150. With the stuff set to arrive in such a big way on the market, we should logically expect an all-aluminum Toyota Camry or Honda Accord soon, right? Um, wrong. Reuters has a great report on what's keeping Asian manufacturers away from aluminum, and it demonstrates yet another stark philosophical difference between automakers in the east and those in the west. Of course, there's a pricing argument at play. But it's more than just the cost of aluminum sheet (shown above) versus steel. Manufacturing an aluminum car requires extensive retooling of existing factories, not to mention new relationships with suppliers and other logistical and financial nightmares. Factor that in with what Reuters calls Asian automaker's preference towards "evolutionary upgrades," and the case for an all-aluminum Accord is a difficult one. Instead, manufacturers in the east are focusing on developing even stronger steel as a means of trimming fat, although analysts question how long that practice can continue. Jeff Wang, the automotive sales director for aluminum supplier Novelis, predicts that we'll see a bump in aluminum usage from Japanese and Korean brands in the next two to three years, and that it will be driven by an influx of aluminum-based vehicles from western automakers into China. Only time will tell if he's proven right. News Source: ReutersImage Credit: Sean Gallup / Getty Images Plants/Manufacturing Honda Hyundai Mazda Nissan Toyota Technology aluminum

Recharge Wrap-up: TRD Toyota Prius, new Hyundai Tucson Fuel Cell dealer

A new study predicts that biofuels capacity will grow to 61 billion gallons per year by 2018. The findings from Lux Research also suggest that biodiesel and ethanol will make up 96 percent (about 5.76 billion gallons) of that. Sixty-four percent of biofuels will come from the Americas, led by the US and Brazil, but with Colombia and Argentina emerging as important producers. Other large emerging producers are China, Indonesia, and Thailand in Asia, and Portugal, Poland, and France in Europe. A large share of next-generation biofuels are expected to come from waste oils. Read more at Domestic Fuel. Images of Toyota Racing Development equipment for the 2016 Prius have leaked. The images show what are likely cosmetic upgrades for the JDM version of the hybrid, including a rear spoiler, front spoiler lip, extended side skirts and a selection of wheels ranging from 15 to 18 inches. Also shown are LED daytime running lights and a dual-tip, centrally mounted exhaust. Expect to see the official reveal of the TRD Prius at the Tokyo Motor Show, where there will surely be more details about the add-ons, including the possibility of some interior features. See the leaked images and read more at Motor1. A fourth Hyundai dealer in southern California now sells the Tucson Fuel Cell. Keyes Hyundai in northern Los Angeles has met the requirements to sell the hydrogen-powered CUV. So far, Hyundai has delivered more than 75 Tucson Fuel Cell vehicles, which have logged almost 700,000 miles on southern California roads. "Keyes Hyundai is thrilled to be added as a qualified dealer for Hyundai's zero-emissions Tucson Fuel Cell hydrogen electric vehicle," says David Kohan, the dealership's general manager. "Our location in the northern Los Angeles region makes it even more convenient for local residents to conveniently acquire their new Tucson Fuel Cell CUV, helping reduce greenhouse gas emissions." The other qualified dealerships are located in Anaheim, Carson and Tustin. Read more in the press release below. Keyes Hyundai In Los Angeles Added To Growing Collection Of Hyundai Tucson Fuel Cell Dealers Keyes Hyundai Joins Tustin Hyundai, Win Hyundai in Carson and Hardin Hyundai in Anaheim as a Qualified Hydrogen Fuel Cell Dealer LOS ANGELES, Sept. 22, 2015 /PRNewswire/ -- Keyes Hyundai in Los Angeles became the fourth qualified dealer for Hyundai's zero-emissions Tucson Fuel Cell hydrogen electric vehicle today. Hyundai is the only manufacturer in the U.S.