Hasta La Gadget!

Ford has announced that it has teamed up with Weyerhaeuser to develop automotive applications for natural fiber materials. Ford is looking into the use of tree fibers called cellulose in some of the plastic composites used to produce its automobiles. Ford says that the use of cellulose in automotive applications has the potential to significantly reduce carbon dioxide emissions and weight.

Another benefit of using the natural fibers is that Ford claims it could speed processing time by as much as 40%. Ford and its partner are working to develop a more sustainable plastic composite material for future vehicle components. This cellulose material isn’t the first natural fiber the Ford has used in its vehicles. The automaker is already using a soybean-based cushion in its vehicles that saves about 5,000,000 pounds of petroleum annually.

The plastic composite Ford is developing using the cellulose fibers from trees would be used in place of fiberglass or mineral reinforcements. The fibers used in the new composite are taken from sustainably grown and harvested trees and related byproducts such as chips. Ford has already concluded during research that the cellulose-based plastic composite material meets requirements for stiffness, durability, and temperature resistance.

One of the significant upsides is that plastic components constructed using the cellulose-based plastic composite weigh 10% less and can be produced 20 to 40% faster with less energy than fiberglass-based materials. Less weight is important and is a major component automakers are dressing to meet future CAFE standards. The lighter a vehicle is, the less fuel it consumes to travel at the same speed over the same distance.

Ford working on natural fiber materials for automotive applications is written by Shane McGlaun & originally posted on SlashGear.
© 2005 – 2012, SlashGear. All right reserved.

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Many manufacturers who are heavily into battery production, and usage are doing all they can to reduce their need for rare earth metals. China has the majority of the world supply of rare earth metals and has been increasing its grip on the materials to drive prices up. Ford has announced that its new lithium-ion batteries were designed to reduce the use of rare earth metals.

The batteries will be used in Ford’s Fusion Hybrid and the C-Max Hybrid. Ford says that the batteries it uses in these hybrid vehicles are more efficient and more powerful and will reduce Ford use of rare earth metals by up to 500,000 pounds annually. Ford says the rare earth metal Dysprosium, the rarest and most expensive used in Ford vehicles, has been reduced by about 50% in the batteries.

Not only does reducing the need for rare earth metals reduce Ford’s dependence on foreign materials; it also allows the company to make their hybrid vehicles cheaper. Ford says that by reducing the rare earth metals it needs in the battery packs the cost of its third-generation hybrid technology was reduced by 30%. That reduction in costs in battery manufacturing is one of the main factors Ford attributes the C-Max Hybrid’s $25,995 starting price too.

Before moving to lithium-ion batteries with a reduced need for rare earth metals, Ford used nickel-metal-hydride batteries in its vehicles. Lithium-ion batteries are 50% lighter and 25 to 30% smaller than comparable nickel-metal-hydride batteries. That means that the vehicles the batteries are used in can be made lighter resulting in better fuel economy and longer driving range for electric vehicles. Ford has also reduced the use of rare earth metals by 50% in the magnets that are used in the hybrid systems electric machines.

Ford reduces the use of rare earth metals in lithium-ion batteries for hybrids is written by Shane McGlaun & originally posted on SlashGear.
© 2005 – 2012, SlashGear. All right reserved.

Cutting-edge technology has a way of aging and trickling down into consumer products. This is particularly true in technology and materials intended for space travel. Ford has announced that it is using a superalloy that was developed for space shuttle engines in the turbocharger for its 2.0-liter turbocharged EcoBoost engine in some applications. The super alloy allows the turbocharger to last significantly longer than using normal metal alone.

The special space shuttle superalloy helps the turbocharger Ford uses survive at the upper limit of temperature extremes that a commercial turbocharger is subjected to. Superchargers using the special alloy will be used on the Fusion and Focus ST EcoBoost turbos. Ford’s 2.0-liter turbocharged engine uses this special alloy for the turbine wheel inside the turbocharger.

The metal provides an upper temperature limit of 1050°C for the special-use turbochargers compared to the standard turbocharger upper temperature limit on 2.0-liter EcoBoost engine versions used in the Edge and Explorer of 970°C. The extra temperature range makes for a more durable turbocharger allowing drivers to enjoy the vehicles for years to come without worrying performance will degrade.

The turbochargers Ford uses are BorgWarner K03 units that use water and oil cooling. The turbos are primarily oil cooled, but the water cooling system creates a thermal water siphon to continue to cool the turbo once the engine is shut off. Ford says that the turbo is designed to run safely at speeds of up to 190,000 RPMs.

Ford uses rocket engine alloy for superior turbos is written by Shane McGlaun & originally posted on SlashGear.
© 2005 – 2012, SlashGear. All right reserved.

Ford is understandably proud of its C-Max Hybrid vehicle and continues to tout the car’s fuel sipping prowess compared to the Toyota Prius V. The C-Max Hybrid was rated by the EPA for 47 mpg in the city and 47 mpg on the highway. That 47 mpg rating both in the city and on the highway is unusual. Typically, hybrids have better fuel efficiency in the city.

Ford is now bragging that it’s C-Max can drive 570 miles on a single tank of gas. By comparison, the Toyota Prius V is capable of driving only 450 miles on a single tank of fuel. That means that the C-Max driver can go an additional 120 miles before stopping to fill up with fuel compared to the Toyota.

The C-Max driver won’t be spending a lot of time at the gas station. The 570-mile driving range on a full thinking gas is enough fuel to take a driver from Los Angeles to Las Vegas and back on a single tank. Hybrid vehicles are traditionally more efficient in the city because they often take advantage of start/stop technology and regenerative braking.

Ford used a number of innovations in the C-Max that allows the efficiency to continue at highway speeds where there is no start and stop driving. Not only is the C-Max Hybrid more fuel-efficient than Prius V while offering an extra 120 miles of driving per tank of fuel, it’s also cheaper. The C-Max starts at a base price of $25,995.

That’s $1300 cheaper than comparable Prius V. Other features of the C-Max Hybrid include EV mode where the vehicle can travel on battery power alone up to 62 mph. The vehicle also has 188 net horsepower making it more powerful than the Prius V. The C-Max also has more passenger space than the Toyota as well.

Ford C-Max Hybrid can go 570 miles on a single tank of gas is written by Shane McGlaun & originally posted on SlashGear.
© 2005 – 2012, SlashGear. All right reserved.