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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.

Feds allege widespread Volkswagen cheating on clean-air rules

Volkswagen intentionally installed software in nearly a half-million diesel vehicles that helped the cars evade substandard results on emissions tests, the federal government charged Friday. The Environmental Protection Agency issued a notice of violation to the German automaker, saying the company's software broke the law by violating two provisions in the Clean Air Act. Circumventing the standards meant affected cars emitted as much as 40 times the allowable level of certain pollutants. Both the EPA and California Air Resources Board have launched investigations. In its notice of violations, the EPA said Volkswagen officials admitted to installing and concealing what they call a "defeat device," which was designed to detect when the cars were undergoing official emissions tests – and only turn on emissions controls during that time. "Our goal now is to ensure that the affected cars are brought into compliance, to dig more deeply into the extent and implications of Volkswagen's efforts to cheat on clean air rules, and to take appropriate further action," said Richard Corey, executive officer of CARB. The allegations cover approximately 482,000 vehicles sold in the United States over the past seven years. Cars involved include diesel versions of the Jetta, Beetle, Audi A3 and Golf manufactured between the 2009 and 2015 model years. Passats manufactured for the 2014 and 2015 model years are also included. Federal officials note there is no safety danger to motorists, but the cars will be recalled for repairs. If true, Volkswagen faces a fine that could run in the hundreds of millions of dollars -- likely higher than the $300 million charge the EPA levied last November at Hyundai and Kia for exaggerating the fuel-economy in several models. The charges also put a tremendous dent into the company's plans to increase sales of its "Clean Diesel" vehicles in North America. In a written statement, Volkswagen Group of America acknowledged it had received the notices from the EPA and CARB. "VW is cooperating with the investigation; we are unable to comment further at this time," it said. Federal officials said the defeat-device software was uncovered during an independent analysis by researchers at West Virginia University, who in working with the International Council on Clean Transportation, a non-governmental organization, raised questions about emissions levels.

Audi considering other variants, turbo V6 for R8

More details from the Audi R8 event at Spain's Ascari circuit have met the Internet, and they provide more intel on the supercoupe will evolve over the second generation. First, they note some small differences in stance with this new car, being wider than the current car and sitting 30 millimeters (1.18 inches) lower. Compared to its Lamborghini Huracan brother, it gets three extra centimeters in the wheelbase. Filling out the power numbers, the 'entry-level' V10 engine at launch rolls out 540 horsepower and 399 pound-feet of torque, does the 0-60 mile per hour dash in 3.5 seconds, and hits a top speed of 200 mph. The V10 Plus model rocks 620 hp and 412 lb-ft, which slices 0.3 seconds off that acceleration time and adds five more mph to the top speed. They'll transfer their power through a seven-speed S-tronic that shifts faster than before, and it will in turn send power through an electronically-controlled clutch at the front axle and a constantly variable limited-slip differential at the rear axle. The power split is said to default to 42/58 front-to-rear, but 100 percent of the torque can be sent fore or aft. Benchmarked against the 991-series Porsche 911, driving sensations travel through an electromechanical steering setup that can be had with a variable rack if preferred, leading to standard 19-inch wheels with the option of 20-inchers and tires developed specifically for this car. A Performance setting offers dry, wet, and snow modes; that first setting turns the ESC off except for situations of impending doom, and Audi racer and test driver Frank Stippler told Top Gear that understeer is reduced, to which TG added "it oversteers at will." Stippler said it's "a lot closer to the GT3 race car than ever before," and even though it's "a lot" less intense than the Huracan, it's just as fast on the track. His estimate is that the new R8 will lap the Nurburgring between ten and 15 seconds faster than the current car. R8 technical lead Roland Schala said the new chassis opens up new avenues of development because "there's no problem to change it," mentioning models like a Clubsport or Superleggera as no longer forbidden. Differentiation could come from a wider engine mix, too. Markets like China need smaller displacements, so Audi's twin-turbo V8 is expected to join the line-up at some point, bringing 500 horsepower.