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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.

Audi to blitz 1.5M sales goal two years ahead of schedule

Audi doesn't seem to be having any trouble of hitting its relatively audacious sales goal of two million units by 2020 - it's already on pace to eclipse 1.5 million sales two years ahead of schedule. According to Reuters, the Volkswagen-owned brand rode a wave of sales in China and the US to pace the early goal, with 780,500 deliveries at the halfway point of 2013. Particularly hot models include the Q5 crossover seen above and A4 sedan. Unless things go poorly in the second half of the year, 1.5 million sales shouldn't be an issue.
That leaves it trailing BMW by just 24,000 units for the global luxury sales crown. If sales trends keep up, Audi will succeed in hitting its goal of two million units and besting its cross-country rival in Munich. Audi CEO Rupert Stadler smells blood, telling German newspaper Handelsblatt, ''We have overtaken Mercedes-Benz and we are now closer to BMW than ever before."

Audi unveils A3 Sportback G-Tron with bi-fuel power, 808-mile range

By this time next year, the Audi A3 Sportback will be offered with a variety fuel-efficient powertrains ranging from diesel to the all-electric E-Tron, but perhaps the most interesting is the all-new G-Tron model, which uses Audi's innovative carbon-natural compressed natural gas called e-gas. Previously called A3 TCNG, we first heard about this technology last year, but now Audi has confirmed that this low-emission, sustainable-fuel will debut by the end of this year on the A3 Sportback G-Tron.
To create this e-gas, a plant in Werlte, Germany uses electricity to split water into hydrogen and oxygen. As hydrogen fuel cell vehicles become more popular, Audi says that this process could also be used to produce hydrogen fuel, but to create CNG, it mixes the hydrogen with carbon dioxide to create "synthetic methane." Since it is identical to the CNG available today, Audi's e-gas can be shipped and stored using the existing CNG infrastructure. Making the whole process even greener, Audi obtains the CO2 for this process from a nearby biogas plant, which would otherwise be released into the atmosphere.
Differentiated from the regular versions of the A3, the G-Tron features a pair of tanks under the rear cargo floor holding 15.43 pounds of CNG, which can power the car for almost 250 miles. What's more, the A3's conventional gasoline tank is still in place, giving the car an addition 560 miles of range. In total, that means the A3 G-Tron has a driving range of more than 800 miles. To run on both CNG and gas, Audi made changes to the car's 1.4-liter four-cylinder engine (including the turbo, cylinder head and fuel injection system) and catalytic converter.