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US expands probe into ZF-TRW airbag failure-to-deploy to 12.3 million vehicles

DETROIT — U.S. auto safety regulators have expanded an investigation into malfunctioning airbag controls to include 12.3 million vehicles because the bags may not inflate in a crash. The problem could be responsible for as many as eight deaths. Vehicles made by Toyota, Honda, Kia, Hyundai, Mitsubishi and Fiat Chrysler from the 2010 through 2019 model years are included in the probe, which was revealed Tuesday in documents posted by the National Highway Traffic Safety Administration. It involves airbag control units made by ZF-TRW that were installed in the vehicles. The control units can fail in a crash, possibly because of unwanted electrical signals produced by the crash itself that can disable an air bag control circuit housed in the passenger compartment, according to NHTSA documents. The electrical signals can damage the control circuit, the documents say. ZF, a German auto parts maker which acquired TRW Automotive in 2015, said in a statement that it's committed to safety and is cooperating with NHTSA and automakers in the investigation. The case is another in a long list of problems with auto industry airbags, including faulty and potentially deadly Takata airbag inflators. At least 24 people have been killed worldwide and more than 200 injured by the inflators, which can explode with too much force and hurl dangerous shrapnel into the passenger cabin. The inflators touched off the largest series of automotive recalls in U.S. history involving with as many as 70 million inflators to be recalled by the end of next year. About 100 million inflators are to be recalled worldwide. On April 19, NHTSA upgraded the ZF-TRW probe from a preliminary evaluation to an engineering analysis, which is a step closer toward seeking recalls. So far, only Hyundai and Kia and Fiat Chrysler have issued recalls in the case. Four deaths that may have been caused by the problem were reported in Hyundai-Kia vehicles and three in Fiat Chrysler automobiles. NHTSA opened an investigation in March of 2017 involving the TRW parts in Hyundais and Kias. The upgrade came after investigators found two recent serious crashes involving 2018 and 2019 Toyota Corollas in which the airbags did not inflate. One person was killed. Jason Levine, executive director of the Center for Auto Safety, a nonprofit consumer group, said the ZF-TRW case shows the auto industry thus far has learned very little from Takata.

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

Old Toyota Camry Hybrid batteries find new life in Yellowstone

Beginning this fall, used hybrid batteries that would otherwise be recycled will get a second life in Yellowstone National Park. 208 nickel-metal hydride batteries are being retired from the Toyota Camry Hybrids they once helped power and will become part of an off-the-grid energy system at Yellowstone's remote Lamar Buffalo Ranch field campus. The Lamar campus provides field seminars and other education and research in the northeastern corner of the park. The energy stored in the battery packs will come from solar panels and micro-hydro turbines. The total storage capacity of the batteries is 85 kWh, which is sufficient to provide plenty of emissions-free power to the five buildings at the field campus. Toyota says this program essentially doubles the life of the batteries that are no longer suitable for driving. It's great to see the batteries get another life cycle before recycling, especially in a place where wild animals easily outnumbers the cars. The battery project is part of a larger partnership between Toyota and Yellowstone. Toyota has previously donated a RAV4 and $50,000 to support sustainability projects at the park. In addition to the energy system being implemented at the Lamar Buffalo Ranch, Toyota has taken part in similar energy projects. Beginning last year, Toyota dealers in Japan have been using hybrid batteries for power storage. Also, Toyota Motor Manufacturing Alabama is testing a system to use hybrid batteries to power operations and for emergency backup power. Learn more in the press release from Toyota below. Buffalo and Bears and Batteries – Oh My! Toyota Brings Power to Yellowstone National Park June 04, 2014 Yellowstone...Where the Deer and the Antelope and the Prius Play Torrance, Calif. (June 4, 2014) – The nation's oldest National Park is ready for some new power. Toyota Camry hybrid batteries will soon power the Lamar Buffalo Ranch field campus in Yellowstone National Park. It's a new lease on life for the batteries and new, zero emission, energy option for the Park. Now that's a "bear-able" solution! The stationary distributed energy system will feature 208 used Camry Hybrid nickel-metal hydride battery packs and a total storage capacity of 85 kWh, more than enough pluck to power the five buildings on the Ranch field campus.