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Ford finds flex-fuel engine design plays big role in emissions output

How bad is ethanol for your engine? There's been a lot of debate on this issue as the US considers upping the biofuel content in the national gasoline supply from 10 percent (E10) to 15 percent (E15). The ethanol industry and some scientists say higher ethanol blends show no "meaningful differences" in new engines while the oil industry says ethanol creates health risks. Researchers working at the Ford Research and Innovation Center decided to take a closer look at how a wide range of gas-ethanol blends - E0, E10, E20, E30, E40, E55 and E80 - affected the emissions coming out of a flex-fuel 2006 Mercury Grand Marquis. To see the full report, printed in the journal Environmental Science & Technology, requires payment, but there is an abstract and Green Car Congress has some more details. The gist is that, "with increasing ethanol content in the fuel, the tailpipe emissions of ethanol, acetaldehyde, formaldehyde, methane, and ammonia increased." At least NOx and NMHC emissions decreased. The researchers say that the effects are due to the fuel and "are expected for all FFVs," but that the way that a manufacturer calibrates the engine will affect NOx, THC, and NMOG emissions. It's this last bit that's important, since the researchers found, "Higher ethanol content in gasoline affects several fundamental fuel properties that can impact emissions. ... These changes can have positive or negative effects that can depend on engine design, hardware, and control strategy. In addition to direct emissions impacts, higher ethanol content fuel can also provide more efficient combustion and overall engine operation under part-load conditions and under knock-limited higher-load conditions." So, as we head towards more ethanol in our fuel supply (maybe), manufacturers are going to need to learn how to burn it most efficiently.

Need for Speed movie casts Mustang in hero car role

Dreamworks Studios, Electronic Arts and Ford Motor Company announced today that the Ford Mustang will play the lead hero car role in the upcoming Need for Speed movie, slated to hit theaters next February. Of course, the Mustang didn't audition for the role like we imagine the film's star, Aaron Paul of Breaking Bad fame, might have. Rather, Ford and Dreamworks struck a partnership deal that meant the Mustang could skip the casting couch. The deal will also see the film's universe populated with other Ford products (gratuitously so, we're guessing), and the automaker will also help the studio promote the video-game-turned-movie next year.
The hero car in question is a special one-off Mustang created by Ford that is making its debut at the E3 video game trade show as we speak. Powered by a supercharged V8 and apparently based on the Shelby GT500, the car's been modified with a widebody kit, 22-inch wheels, larger air intakes and twin hood nostrils. Ford also provided the film's production with an F-450 truck that will be called "The Beast" in the film's story, and a second Mustang to be used during filming as a camera car.
The Mustang's movie career is really taking off, with news of its Need For Speed casting closely following last week's release of the trailer for Getaway, a movie coming out in August that stars Ethan Hawke, Selena Gomez and another Shelby GT500. In addition to Aaron Paul and a modified Mustang, the Need For Speed movie also stars Michael Keaton (cop, we're guessing) and Dominic Cooper (villain, we're guessing), and is directed by Scott Waugh, who directed the Navy SEAL film Act of Valor in 2012.

Ford cleans up painting process with cameras

Knowing how the bacon gets made rarely entices us and, in the same vein, the same usually goes for knowing about how new cars get painted. But in both instances, however, quality - or a lack thereof - is instantly obvious. In terms of the latter, Ford is showing off its new paint quality process with 3D Dirt Detection Technology to find imperfections in vehicle paint more easily and more quickly.
This process - being performed on the F-150 SVT Raptor above - uses 16 computer-controlled cameras to create a three-dimensional model (inset) of the vehicle to detect flaws in the paint including dirt particles, which can then be buffed out manually. Ford says this new technology cuts down on time spent looking for paint flaws and gives workers more time to correct those that are discovered.
Currently, Ford only uses its 3D Dirt Detection Technology system at three factories (the Dearborn, MI facility, along with those in Louisville, Kentucky and Valencia, Spain), but it will soon spread to five more plants in North America. Ford has released a video and press release for this innovative and unexpectedly interesting process, both of which are posted below.