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Brand new cars are being sold with defective Takata airbags

If you just bought a 2016 Audi TT, 2017 Audi R8, 2016–17 Mitsubishi i-MiEV, or 2016 Volkswagen CC, we have some unsettling news for you. A report provided to a US Senate committee that oversees the US National Highway Traffic Safety Administration (NHTSA) and reported on by Automotive News claims these vehicles were sold with defective Takata airbags. And it gets worse. Toyota and FCA are called out in the report for continuing to build vehicles that will need to be recalled down the line for the same issue. That's not all. The report also states that of the airbags that have been replaced already in the Takata recall campaign, 2.1 million will need to eventually be replaced again. They don't have the drying agent that prevents the degradation of the ammonium nitrate, which can lead to explosions that can destroy the airbag housing and propel metal fragments at occupants. So these airbags are out there already. We're not done yet. There's also a stockpile of about 580,000 airbags waiting to be installed in cars coming in to have their defective airbags replaced. These 580k airbags also don't have the drying agent. They'll need to be replaced down the road, too. A new vehicle with a defective Takata airbag should be safe to drive, but that margin of safety decreases with time. If all this has you spinning around in a frustrated, agitated mess, there's a silver lining that is better than it sounds. So take a breath, run your fingers through your hair, and read on. Our best evidence right now demonstrates that defective Takata airbags – those without the drying agent that prevents humidity from degrading the ammonium nitrate propellant – aren't dangerous yet. It takes a long period of time combined with high humidity for them to reach the point where they can rupture their housing and cause serious injury. It's a matter of years, not days. So a new vehicle with a defective Takata airbag should be safe to drive, but that margin of safety decreases with time – and six years seems to be about as early as the degradation happens in the worst possible scenario. All this is small comfort for the millions of people who just realized their brand-new car has a time bomb installed in the wheel or dashboard, or the owners who waited patiently to have their airbags replaced only to discover that the new airbag is probably defective in the same way (although newer and safer!) as the old one.

Researchers halfway to cutting carbon fiber costs by 90%

Carbon fiber has been utilized for decades to build racecars, as a means to cut weight while maintaining strength. But until recently, the space-age material has been largely absent from the street on anything but supercars because of the expense to use it. Recently, BMW signaled a major shift in that trend when it starting using carbon fiber reinforced plastic panels on the i3 and i8. This relatively small scale start might be just the beginning; the German company believes that a breakthrough to inexpensively manufacture the lightweight stuff is just on the horizon.
MAI Carbon Cluster Management GmbH counts BMW, Audi, Airbus, the German government and many other organizations as supporters, and it's researching how to make carbon fiber cheaper to produce, according to Automotive News Europe. The company thinks it can reduce costs by 90 percent in the near future. "We've certainly reached a halfway point on our cost-cutting target for suitable carbon-fiber parts," said project head Klaus Drechsler to Automotive News Europe.
Unfortunately, it isn't entirely clear just what MAI Carbon is doing to make such a huge leap possible. However, a recent post on the company's website talks about a new form a carbon fiber using a thermoplastic matrix that could be cured in less than three minutes. That's compared to about 90 minutes in the traditional process with an autoclave.

Audi sets diesel records on road and track

Ever the proponent of diesel propulsion, Audi has claimed two very different kinds of records in Europe with its finest oil-burners. The more exciting of the two was achieved recently at the Sachsenring, where the Audi RS5 TDI Competition Concept posted the fastest diesel-powered lap time ever recorded on the track. As you may recall, Audi revealed the RS5 TDI Concept last year, swapping the gasoline-burning 4.2-liter V8 in the production RS5 coupe for a 3.0-liter V6 diesel with two turbochargers and an electric supercharger. The result was 385 horsepower and 553 pound-feet of torque, but Audi's been working on the prototype over the course of the past year. In the new Competition version, output is up to 435 hp and 590 lb-ft, and despite the inherently heavier diesel engine, it actually weighs 531 pounds less than the production model. That helped the RS5 TDI Competition lap the circuit in 1:35.35, besting the previous diesel lap record by 1.87 seconds, and adding to the Hockenheim record it took previously. Around the same time, another team set out from Maastricht in the Netherlands in an Audi A6 TDI Ultra and drove it for 28 hours straight, hitting 14 countries and logging 1,158.9 miles on a single tank of diesel. The achievement, certified by Guinness World Records, was completed in a showroom-stock vehicle, with automotive journalist Andrew Frankel and racing driver Rebecca Jackson splitting driving duties. They achieved an average of 75.9 miles per gallon – much better than the advertised rating of 67 mpg – as they cruised through from Holland to Hungary, passing along the way through Belgium, Luxembourg, France, Switzerland, Lichtenstein, Austria, Germany, Italy, Slovenia, Croatia, Bosnia, and Serbia. Record: Audi RS 5 TDI competition concept drives to record time on the Sachsenring track - Audi sets new lap record for cars with diesel engines - Superior technology platform with 435 hp and 800 Nm (590.0 lb-ft) - Electric compressor: overcomes turbo lag, enhances sprint performance Audi has set a new record time on the Sachsenring for cars with a diesel engine. The Audi RS 5 TDI competition concept rounded the 3.6 km (2.2 mi) race course in a time of 1 minute 35.35 seconds. The technology platform draws its power from a 3.0-liter V6 biturbo TDI with 320 kW (435 hp) of power and 800 Nm (590.0 lb-ft) of torque. The highlight is an electrically driven compressor.