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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.

Chrysler, Nissan minivans earn 'dire' crash test results, says IIHS [w/video]

First introduced in 2012, the Insurance Institute for Highway Safety's small-overlap frontal crash test has become the bane of many auto engineers' existence. It's a particularly steep design challenge because it forces just 25 percent of a vehicle's front end to take the brunt of a 40-mile-per-hour impact. The newly released results of four family-minded minivans underscore just how difficult the crash test is: only one scored an Acceptable rating, and the other three did very poorly. The 2008-2015 Chrysler Town & Country and Dodge Grand Caravan, plus the 2011-2015 Nissan Quest, all received Poor ratings in the test, the IIHS' lowest possible score. The three of them showed significant crash intrusion into the driver's area. The dummy in the Nissan actually had to be cut out of the vehicle, with an IIHS spokesperson remarking, "the structure collapsed like a house of cards." In the Fiat Chrysler Automobile vans, the steering wheels moved out of the way, making the airbag less effective and letting the driver's head hit the dashboard. While it was not actually crashed, the agency is also giving the 2009-12 Volkswagen Routan a Poor score because it shares a structure with the FCA models. The newly released results of four minivans underscore just how difficult the small-offset crash test is. The refreshed 2015 Toyota Sienna (shown), conversely, earned an Acceptable rating and is also a Top Safety Pick+ because of its optional forward collision warning and automatic braking system. While the crash test dummy moved around during the impact more than the agency would have liked, sensors showed a low risk of injuries. The IIHS tested the Honda Odyssey last year, and it earned a Good overall score, the agency's best ranking. It's also a Top Safety Pick+ vehicle. The only member of the minivan segment left to test is the latest Kia Sedona, and the Institute is reportedly waiting a little longer for Kia to make changes to improve the model's performance. When reached for comment, Nissan spokesperson Steve Yaeger provided Autoblog with the following statement: "Nissan is committed to vehicle safety and believes that consumers should have information about crash protection so they can make educated buying decisions. Nissan is proud of the 2014 Quest's "good" rating in the IIHS front moderate overlap and side impact tests as well as a "good" head restraint rating.

These are the cars with the best and worst depreciation after 5 years

The average new vehicle sold in America loses nearly half of its initial value after five years of ownership. No surprise there; we all expect that shiny new car to start depreciating as soon as we drive it off the lot. But some vehicles lose value a lot faster than others. According to data provided by iSeeCars.com, trucks and truck-based sport utility vehicles generally hold their value better than other vehicle types, with the Jeep Wrangler — in both four-door Unlimited and standard two-door styles — and Toyota Tacoma sitting at the head of the pack. The Jeep Wrangler Unlimited's average five-year depreciation of 30.9% equals a loss in value of $12,168. That makes Jeep's four-door off-roader the best overall pick for buyers looking to minimize depreciation. The Toyota Tacoma's 32.4% loss in initial value means it loses just $10,496. The smaller dollar amount — the least amount of money lost after five years — indicates that Tacoma buyers pay less than Wrangler Unlimited buyers, on average, when they initially buy the vehicle. The standard two-door Jeep Wrangler is third on the list, depreciating 32.8% after five years and losing $10,824. Click here for a full list of the top 10 vehicles with the least depreciation over five years. On the other side of the depreciation coin, luxury sedans tend to plummet in value at a much faster rate than other vehicle types. The BMW 7 Series leads the losers with a 72.6% drop in value after five years, which equals an alarming $73,686. BMW's slightly smaller 5 Series is next, depreciating 70.1%, or $47,038, over the same period. Number three on the biggest losers list is the Nissan Leaf, the only electric vehicle to appear in the bottom 10. The electric hatchback matches the 5 Series with a 70.1% drop in value, but since it's a much cheaper vehicle, that percentage equals a much smaller $23,470 loss. Click here for a full list of the top 10 vehicles with the most depreciation over five years.