NEWS BRIEFS FOR THE WEEK

Jan. 1, 2020
MO Proposes To Repeal State Safety Inspection Program ... Register Your National Car Care Month Vehicle Check-Up Event ... "Nanoskins" Pave The Way For Flexible Conductivity In Automotive Sensors ... Senate Committee Passes Small Business Health Plan
NEWS BRIEFS FOR THE WEEK 
OF MARCH 23, 2006
MO Proposes To Repeal State 
Safety Inspection Program

WASHINGTON, DC (March 2, 2006) - Missouri State Senator John E. Greisheimer (R-District 26) has introduced Senate Bill 583, which would change the state's emissions testing programs. Senator David G. Klindt (R-District 12) has offered an amendment to the bill that would repeal all safety inspections for vehicles in Missouri. As of the end of February, the Missouri State Senate voted to approve the bill. Although this is just an initial approval and S. 583 has yet to be passed to the Missouri House of Representatives, many are concerned that Klindt's amendment could become law.

The Automotive Service Association (ASA) released a press statement opposing the repeal of the Missouri Vehicle Safety Inspection Program.

If passed, the amendment to abolish the safety inspection program will become effective Jan. 1, 2007. Some senators expressed that the program is more of a hassle to consumers than it is a helpful tool in maintaining safety on the roads.

Currently, vehicles in Missouri only have to pass safety inspection every two years before being licensed again. An estimated 3 million vehicles are inspected annually in Missouri with an average of 16 percent - approximately 480,000 - of those vehicles failing to meet inspection standards. 

ASA has taken the position that repealing the state's safety inspection program would allow these and other substandard vehicles to be out on the road. The association argues that vehicles that fail inspection not only put the driver and others at risk, but in some incidences these vehicles cause fatalities. A fatal crash analysis conducted over the course of two years shows that Missouri's fatal accident rate is much lower than the national average. In states with required inspections, the average fatal accident rate is only 1 in 78.1 accidents. Nationally, the fatal accident rate is 79.4 compared to Missouri's fatal accident rate of 1 in 132.2 accidents. All of these averages are based on fatal crash statistics in which a defective vehicle is to blame, according to the Missouri State Highway Patrol.

"Missouri's inspection program has been a model for other states interested in developing safety inspection programs or enhancing a current program," said Bob Redding, ASA's Washington, DC, representative. "Two important issues continue to harm state safety inspection programs. First, we have continued backlash from the public relations disaster of emissions inspection programs in the 1990s. Second, as the U.S. Government Accountability Office pointed out in a state vehicle safety inspection program review, there is a woefully inadequate amount of data correlating accidents, injuries and deaths with states that have vehicle safety inspection programs and those that do not. To date, the National Highway Traffic Safety Administration has shown little interest in developing this data or promoting vehicle safety inspection programs."

ASA is asking Missouri repairers and vehicle owners to contact their state representatives and inform these legislators that they oppose the repeal program. The association encourages individuals to visit its legislative Web site at www.TakingTheHill.com for more information, including legislator contact information and letter-writing tips.

(Source: ASA)

Register Your National Car Care Month Vehicle Check-Up Event BETHESDA, MD (March 16, 2006) - The Car Care Council (CCC) says that organizations can register their 2006 National Car Care Month vehicle check events on the council's Web site at www.carcare.org. "The National Car Care Month event locator is very popular with motorists who visit the Car Care Council Web site," said Rich White, executive director of CCC. "With more than 150,000 visitors each month, www.carcare.org is the 'go to' place to find vehicle check events throughout the country." In 2005, National Car Care Month vehicle check events were conducted nationwide by independent repair shops and auto parts stores, as well as at vocational schools. "Major distributors to small independent service shops have realized how the 'Be Car Care Aware' campaign, and more specifically, National Car Care Month, can help their businesses," said White.  To help organizations conduct vehicle check events, visitors to the "industry" section of the Council's site will find National Car Care Month materials to enhance their events, including a free vehicle check event planning guide. In addition, "Be Car Care Aware" point-of-sale kits, apparel and premium items are available for purchase. (Source: CCC)"Nanoskins" Pave The Way For Flexible Conductivity In 
Automotive Sensors

TROY, NY (March 14, 2006) - A team of researchers has developed a new process to make flexible, conducting "nanoskins" for a variety of applications within the automotive, electronic, and other industries. 

The new materials bridge a significant gap - combining the strength and conductivity of carbon nanotubes with the flexibility of traditional polymers. "Researchers have long been interested in making composites of nanotubes and polymers, but it can be difficult to engineer the interfaces between the two materials," says Pulickel Ajayan, the Henry Burlage professor of Materials Science and Engineering at Rensselaer Polytechnic Institute. "We have found a way to get arrays of nanotubes into a soft polymer matrix without disturbing the shape, size, or alignment of the nanotubes." 

The newly developed nanoskins have a conducting array of carbon nanotubes embedded in a flexible thin polymer skin.
(Photo: Rensselear Polytechnical Institute/Y.J. Jung)

Nanotube arrays typically don't maintain their shape when transferred because they are held together by weak forces. But the team has developed a new procedure that allows them to grow an array of nanotubes on a separate platform and then fill the array with a soft polymer. When the polymer hardens, it is essentially peeled back from the platform, leaving a flexible skin with organized arrays of nanotubes embedded throughout. 

Nanoskins can be bent, flexed, wrapped and rolled up like a scroll, all while maintaining their ability to conduct electricity, which makes them ideal materials for electronic paper and other flexible electronics, according to Ajayan. In addition, many other applications and products are possible employing nanotubes within flexible substrates. 

For example, the researchers can see their process being used to build flexible miniature pressure sensors and gas detectors. "There are a lot of possibilities if you have an easy way to transfer the nanotubes to any platform, and that is what we have developed," Ajayan says. 

The team has also shown that the flexible nanoskin materials demonstrate an extremely useful physical property called "field emission." When a voltage is applied to the embedded carbon nanotubes, electrons are pulled out from the surface, which can be used to produce high-resolution electronic images. 

(Source: Rensselaer Polytechnic Institute)

Senate Committee Passes 
Small Business Health Plan

WASHINGTON, DC (March 20, 2006) - In a continuation of last week's consideration, the Senate Health, Education, Labor and Pensions (HELP) Committee passed "The Health Insurance Marketplace Modernization and Affordability Act " (S. 1955) by a vote of 11 to 9. The bill was introduced by Senator Mike Enzi (R-WY) and was originally co-sponsored by Senators Ben Nelson (D-NE) and Conrad Burns (R-MT). "The Health Insurance Marketplace Modernization and Affordability Act" would allow business and trade associations to band their members together to procure lower costs on regional or national health plans.

According to the Automotive Aftermarket Industry Association (AAIA), the approval of the HELP Committee marks the first major step for Small Business Health Plans in the Senate for more than the last 15 years. The next step for the legislation will be a vote by the full Senate, tentatively scheduled for late April or early May. Last year, the U.S. House of Representatives passed its version of Association Health Plan legislation (H.R. 525). 

The Senate bill currently does not provide for self funding, whereas the House version does, and the plans would be subject to state oversight, rather than oversight by the U.S. Department of Labor, as in the House version. Should S. 1955 pass the full Senate, the House and Senate bills would go to conference to attempt to reconcile the extensive differences between the bills before a final draft is voted upon.

AAIA is requesting that interested individuals contact their senators urging them to vote in favor of S. 1955. For contact information and letter-writing tips, AAIA members are urged to visit the association's Legislative Action Center at www.aftermarket.org.

(Source: AAIA)

Reduce Fuel Consumption With Ventilated Seats

GOLDEN, CO (March 2, 2006) - Last year the National Renewable Energy Laboratory (NREL) partnered with the EPA and SAE in a project known as Improved Mobile Air Conditioning, aimed at seeking ways to increase energy efficiency and reduce greenhouse gas emissions for vehicles.

The overall technical goals of the IMAC project are to reduce A/C thermal load by 30 percent, increase the coefficient of performance by 30 percent, and reduce emissions by 50 percent. Why focus on A/C systems? Because about 7 billion gallons of fuel-or equivalent to 9.5 percent of the nation's imported crude oil-are used annually just to cool vehicles in the United States.

The map shows the millions of gallons of oil used annually per state to provide air conditioning in vehicles.
(Graphic source: NREL)

In research just released by the NREL Vehicle Ancillary Loads Reduction team, one means to substantially reduce the use of air conditioning has been shown to be effective: ventilated automotive seats not only improve passenger comfort, but also a vehicle's fuel economy. That's because ventilated seats keep drivers and passengers cooler, so they need less air conditioning to be comfortable.

W.E.T. Automotive Systems Ltd. provided NREL with ComfortCools seats for testing. Each seat contains two fans that pull air from the seat surface and out from underneath the seat. General Motors currently offers this ventilated seat as an option for the Cadillac STS.

NREL developed its thermal comfort tools to help the automotive industry design smaller and more efficient climate-control systems in vehicles. The tools consist of a one-of-a-kind thermal comfort manikin called ADAM (ADvanced Automotive Manikin) - which actually breathes and sweats - along with a physiological model and psychological model. Linked together, these tools assess comfort in a transient, non-homogeneous environment, unlike other commonly used models based on steady-state, uniform environmental data.

Using its suite of thermal comfort tools and subjective test data, NREL measured improvement in human thermal sensation for the ventilated seats and the potential for a 7 percent reduction in air-conditioning compressor power. "If all passenger vehicles had ventilated seats, we estimate that there could be a 7.5 percent reduction in national air-conditioning fuel use. That translates to a savings of 522 million gallons of fuel a year," said Project Leader John Rugh.

(Source: NREL)

EPA Seeks Voluntary Action to Reduce Use of Priority Chemicals

WASHINGTON, DC - The U.S. Environmental Protection Agency (EPA) announced a voluntary program under its National Challenge Commitment for Priority Chemicals. The Agency is asking a facility to voluntarily commit to decreasing the use of at least one priority chemical identified by EPA's Office of Solid Waste. EPA would publicly recognize all facilities participating in the program. 

"The list includes 28 organic chemicals and three metals and their compounds that the agency has concluded are being generated in industrial waste," according to EPA. "Priority chemicals are those that are persistent in the environment, accumulate in living organisms and are toxic if released. Metals on the list include cadmium, lead and mercury." 

For more information on EPA's National Challenge Commitment for Priority Chemicals and National Partnership for Environmental Priorities, visit www.epa.gov/epaoswer/osw/conserve/priorities/chemical.htm.

(Source: Automotive Aftermarket Industry Association)

DENSO Announces New 
Environmental Action Plan

SOUTHFIELD, MI (March 14, 2006) - DENSO Corp. announced its new five-year North American Environmental Action Plan. The plan takes effect in April at all DENSO group companies in North America and will serve as a roadmap for the company's North American environmental activities.

"We recognize that while automobiles are an essential part of our daily lives, they do have a negative impact on the environment," said Mitsuo "Matt" Matsushita, DENSO International America president and CEO. "We believe it is our responsibility to do everything we can to reduce that environmental burden."

DENSO's environmental action plan is organized into four categories: 

Eco Products: DENSO will develop products that are lightweight and energy saving and consider environmental improvement. In all of its products, DENSO will reduce its use of resources; control and reduce environmentally hazardous substances such as mercury, cadmium and hexavalent chromium; and integrate environmental planning in the product design stage. 

Eco Factory: The company plans to reduce the environmental impact of its manufacturing facilities (including manufacturing and distribution) through reducing water use to 50 percent of 1999 levels; reducing CO2 emissions by 18 percent in manufacturing facilities and 6 percent in other facilities; reducing landfill waste to 75 percent of 1999 levels; and reducing hazardous substance emissions by decreasing manufacturing facility regulated emissions volume to 30 percent of 2000 levels.

Eco Management: DENSO group companies will develop environmental action plans and reinforce environmental partnerships with suppliers through activities such as developing green procurement guidelines and promoting the purchase of environmentally friendly products.

Eco Friendly: The company's plan also includes encouraging and supporting employee environmental activities; proactive information disclosure and communication with stakeholders; environmental education; and environmental and social contributions. 

"Our ultimate goal is to prevent global warming, recycle resources, and reduce environmentally hazardous substances," said Matsushita. "That is how we'll measure our success rate in each of these four key areas." 
For more information, visit the company's Web site at to www.densocorp-na.com.

(Source: Denso Corp.)

Piezo-Controlled Gasoline Injection System Debuts 

GENEVA, SWITZERLAND (March 2, 2006) - Robert Bosch GmbH debuted its new gasoline direct-injection system that uses a spray-guided combustion process in the Mercedes-Benz CLS 350 CGI at the 2006 Geneva Auto Show. 

Piezo injector for the gasoline injection system.
(Photo: Robert Bosch GmbH)

Central to the system are very fast-switching piezo injectors. The fuel which these injectors spray into the combustion chamber is so finely atomized, says Bosch, that it can be ignited directly without mixing in the combustion chamber - what the experts call a "spray-guided combustion process with stratified charge."

Dr Rolf Leonhard, vice president for Bosch's Development for Gasoline Systems, explained "We are assuming that by 2010, annual production of gasoline engines equipped with direct injection will top 3 million. Gasoline direct-injection with piezo injectors reduces consumption by up to 15 percent compared with today's port fuel injection." He added that besides the piezo valves, a powerful engine management system is an important feature of the system. 

Leonhard also said that the combination of direct injection with turbocharging is another trend that Bosch is pursuing in the development of gasoline engines. In addition to a greater revving range, the engines develop higher torque in the lower speed range. For this application, Bosch has developed the second generation of its DI-Motronic, which, like the piezo system, delivers injection pressures up to 200 bar, but keeps faith with solenoid-controlled injection valves. The product will also be launched in 2006 in a 1.6L engine jointly developed by BMW and PSA, destined for use in the Mini, amongst others. 

(Source: Bosch)

Feds Begin Green 
Nanotechnology Initiative

WASHINGTON (March 9, 2006) - According to the U.S. Department of State's Bureau of International Information Programs (USINFO), experts who specialize in nanotechnology have launched an effort they say will help minimize environmental and health risks that could be associated with such processes and products.

Within sectors such as the auto industry, nanotechnology holds tremendous potential for pollution prevention and sustainability, especially in the areas of clean water, energy and efficient sensors," said David Rejeski, a director of technologies at the Woodrow Wilson International Center for Scholars in Washington. "We are interested in bringing together stakeholders from government, industry, the research community and citizen organizations who are committed to ensuring that nanotechnology helps create a new, more sustainable economy," he added.

Led by Barbara Karn, manager of the U.S. Environmental Protection Agency's (EPA) nanotechnology research program, the initiative involves a series of meetings on "green" nanotechnology. At the first ever GreenNano meeting of February 16, Karn said, "Key nanotechnology companies and researchers are taking responsibility to ensure that nanotech products are produced in environmentally safe ways." A technology must meet three criteria to be considered green: It must be environmentally benign, it must perform better than conventional alternatives and it must be more economical than conventional alternatives.

"The GreenNano series," Karn said, "is designed to explore everything from new nanotechnology products claiming to be better for the environment - because of saved energy, reduced waste, or safer materials used - to smart engineering and business practices." The initiative also will examine government policies that offer incentives for developing such low-risk practices, and highlight research in green nanotechnology applications, including a symposium to be held in Atlanta at the end of this month.

(Source: USINFO)

Dunlop's "Touch Technology" 
Helps Drivers Get a Grip

AKRON, OH (March 2, 2006) - Want to feel the quick response of a tire cornering on a country road? Want to experience tire grip at its peak? Want to sense lightning-fast turn-in when steering a sports car? 

Dunlop introduced Touch Technology, which reflects Dunlop's product development approach which employs a number of sensory technologies, to enable drivers to have an enhanced feel of the road, to be more in control of the drive and to have more fun on the roads. The company unveiled this new technology with its ultrahigh-performance SP Sport Maxx summer tire to motorists at the Geneva Auto Show. 

Andy Traicoff, director of the Dunlop brand in North America, said Touch Technology actually involves several tire advances, including:

* Multi-Radius Tread technology, which ensures even pressure distribution in the contact patch and a larger tire footprint for outstanding dry handling without compromise in the rain.

* Jointless Band technology that helps maintain the tire's smooth performance at highway speeds, uniformity and long tread wear.

* Improved bead seat technology helps deliver a tighter fit between the tire and wheel for noticeably better handling.

* Stiffer high-performance tread compounds help deliver outstanding tire response at highway speeds.

* VersaLoad Technology optimizes the tire footprint on the roadway for consistent handling, ride comfort and tread wear under various loading conditions.

* Improved bead construction helps deliver a noticeably better ride and enhanced driving response.

* A stability rib in the tread design helps maintain constant road contact for consistent wheel response and driving feedback.

* Solid shoulder construction helps provide a solid rib for enhanced handling in cornering.

* Dimensionally Stable Polyester Technology helps maintain tire uniformity for a smooth, responsive drive.

"The technology enables drivers to savor an enhanced feel of the road, to be more in control of the drive and to have more fun on the roads," Traicoff explained. "It's a sensitivity to feel how the tire reacts to changes in the roadway. It allows drivers to push their boundaries further and achieve enhanced performance, quicker handling, more grip, braking power, more control and added enjoyment. This all comes from receiving better feedback from the road."

(Source: Dunlop)

How To Treat A Woman 
In An Auto Repair Shop
BUFFALO, NY (March 1, 2006) - How familiar are you with the role of women in the automotive buying and repair market?  More women purchase and maintain their vehicles than ever before. Yet, for many women, taking care of their cars can be a daunting task - especially if they don't trust their repairman. According to Skip Merrick, automotive chairman at Alfred State College, women impact eight out of 10 vehicle sales and nearly half of tire sales-. That in itself makes it imperative that automotive service professionals understand how to interact with women, and to reap the benefits of sales and repeat business. Merrick has created an ethics training program to help participants understand the vulnerability and intimidation that many women experience when buying a car or seeking repair services. The program is part of a required service manager/consultant course where students learn how to effectively run an automotive business. Through role-playing scenarios and real-life experiences from female students and staff, students learn how women perceive the car buying and repair process.  Some highlights of Merrick's training include: 

* Understand that a woman relies on her car in different ways than a man-. For example, a woman faces a potentially vulnerable and dangerous situation when her vehicle stalls. 

* Never use a condescending tone of voice, inappropriate language or refer to female customers by anything other than their first name.

* Maintain eye contact to communicate sincerity. 

* Avoid using negative body language, such as folding arms, tapping a foot or checking a watch that may communicate boredom or superiority. 

* Female purchasing characteristics also are covered. For instance, women will often drive up to 50 miles to give their business to a repair shop they trust. "Instead of noticing the make and model of the car getting its oil changed, a woman looks for cleanliness, notices body language and seeks respect from whoever greets her," said Merrick. "Many females also admit feeling ignored, talked down to, taken advantage of and even pushed out the door when they interact with dealers or repairmen. And we want to change that." (Source: Eric Mower and Associates) SEMA Memorial Scholarship Funds Available

WASHINGTON (Feb. 24, 2006) - Whether currently enrolled or recently graduated, students may be able to qualify for financial assistance through the SEMA Memorial Scholarship Fund (SMSF). 

SEMA says that it's not a loan. Nor will the money have to be repaid. In fact, the SMSF awards thousands of dollars to students and recent graduates every year. Scholarships are awarded to students pursuing careers in the automotive aftermarket each year. Although money is given to students regardless of SEMA affiliation, 20 percent of all scholarships are reserved specifically for employees of SEMA-member companies or for their dependents. Employees of SEMA-member companies are highly encouraged to apply for a scholarship and to have their children and grandchildren apply.

Those employed by a SEMA-member company who are paying off student loans also are invited to apply for the Loan Forgiveness Program. The program awards money to those who have been working for a SEMA-member company for at least one year.

The deadline to apply for the 2006-2007 program is April 28, 2006. For more information or an application, interested parties can visit www.sema.org/scholarship or e-mail [email protected].

(Source: SEMA)

Controversy Arises Over OSHA's 
New "Permissible Exposure Limit" of Hexavalent Chromium
WASHINGTON, DC (March 21, 2006) - The Occupational Safety and Health Administration (OSHA) has issued new standards to the existing standards that limit workplace exposure to hexavalent chromium. The Agency determined that the current level of hexavalent chromium that workers are exposed to puts them at a significant health risk. In a formal press statement, the Automotive Service Association (ASA) expressed concern about the lowering of the permissible level because of the lack of data as to the potential economic impact the lower level will have on the association's collision shop members. Collision shop employees use many refinishing products in their shops, as well as sand, grind and weld vehicle parts. According to ASA, each of these procedures presents the opportunity for hexavalent chromium to exist. Hexavalent chromium is a metal shown to cause cancer in some workers exposed to it. Evidence demonstrates that workers exposed to hexavalent chromium are at a higher risk of developing lung cancer, asthma, skin damage and destruction of nasal epithelia. More than 500,000 Americans are exposed to the cancer-causing metal. These Americans include steel workers, welders, chrome platers, and paint and pigment manufacturers. Currently, workers associated with hexavalent chromium are permitted, by law, to be exposed to 1 milligram of the hexavalent chromium for every 10 cubic meters of air. The new limit will only allow workers to be exposed to 5 micrograms per cubic meter of air. Although a significant drop in level of exposure, the level is still five times higher than that originally presented by OSHA in 2004, which pales in light of that proposed by worker safety activists who called for such low levels of exposure that saw the final regulation 20 times higher. "ASA is concerned about the requirement of regulated areas where workers would be provided personal protective equipment, washing facilities and changes of clothes. Extensive medical monitoring of workers is also required," said Bob Redding, ASA's Washington, DC representative. "We are troubled by the lack of data as to worker exposure in collision shops. We will need to work closely with OSHA to determine specifically what shops will be obligated to provide." OSHA has acknowledged that the new limit will still allow between 10 and 45 deaths from lung cancer for every 1,000 workers exposed to the harmful particles. These deaths will occur over a 45-year period. The Agency went on to defend its stance by also reporting that as many as 145 deaths caused by lung cancer will be prevented due to the new exposure standards. ASA has posted the final regulation on its legislative Web site at www.TakingTheHill.com. (Source: ASA) Lexus Initiates Spanish Language 
Web Site
TORRANCE, CA (March 6, 2006) - Lexus, already recognized by J.D. Power and Associates as the most useful automobile Web site for new-vehicle shopping, has upped the ante. The company recently launched a Spanish language site at www.lexus.com/espanol. According to Lexus, it is the first Spanish-language Web site created by a luxury automotive brand.
(Photo: Lexus)

The new site features unique images and marketing information. Included is vehicle information on the full line of Lexus luxury cars and SUVs, the Lexus dealer locator, Lexus Certified Pre-Owned information, and the "About Lexus" reference area, which includes Lexus history, awards and accolades and corporate information. Additional content is planned for the future. 

"Growth in the luxury market is steadily increasing among those who predominantly speak Spanish or are bilingual," said Deborah Meyer, Lexus vice president of marketing. "Lexus has a strong core of buyers in the Hispanic community, and many prefer Spanish-language sites when researching or shopping online."

(Source: Lexus)

Say Goodbye to Paper Fuel Filters

BLOOMFIELD HILLS, MI (March 6, 2006) - Modern diesel injection systems rely on fuel that is almost completely free of dirt particles and water. In practice, however, drivers are often confronted with dirty and water-contaminated diesel fuels.

Filtration experts at MANN+HUMMEL have solved this problem with a new, multilayer, high-performance filter media named MULTIGRADE F that is four times more efficient than conventional filter papers. The company says that the filter media will improve initial filtration efficiency from the 85-to-99 percent range to a 95-to-99.9 percent. Diesel fuel filter performance was increased by using melt-blown, superfine fibers combined with a compressed cellulose substrate layer. This multilayer filter media (also called a "fleece") was optimized to greatly increase oil performance and air filter elements. As the automotive industry changes from using paper to high-performance fleece filter media, there will be opportunities to increase engine-oil wear protection in the future and create more compact filter designs.

(Source: MANN+HUMMEL)

Carbon Fiber Cars Could Put U.S. on Highway to Efficiency

OAK RIDGE, TN (March 6, 2006) - Highways of tomorrow might be filled with lighter, cleaner and more fuel-efficient automobiles made in part from recycled plastics, lignin from wood pulp and cellulose. 

First, however, researchers at the U.S. Department of Energy's Oak Ridge National Laboratory (ORNL) - working as part of a consortium with Ford, General Motors and DaimlerChrysler - must figure out how to lower the cost of carbon fiber composites. Progress in developing affordable carbon fiber composites has been steady as ORNL researchers with the support of the University of Tennessee (UT) work to optimize raw materials and spinning processes for alternative forms of carbon fiber precursors from renewable sources.

If they are successful in developing high-volume renewable sources of carbon fiber feedstocks, ORNL's Bob Norris believes they will be on the road to success. "Whereas today the cost to purchase commercial-grade carbon fiber is between $8 and $10 per pound, the goal is to reduce that figure to between $3 and $5 per pound," said Norris, leader of ORNL's Polymer Matrix Composites Group. At that price, it would become feasible for automakers to use more than a million tons of composites - approximately 300 pounds of composites per vehicle - annually in the manufacturing of cars. 

The big advantage of carbon fiber is that it is one-fifth the weight of steel yet just as strong and stiff, which makes it ideal for structural or semistructural components in automobiles. Replacing half the ferrous metals in current automobiles could reduce a vehicle's weight by 60 percent and fuel consumption by 30 percent, according to some studies. The resulting gains in fuel efficiency, made in part because smaller engines could be used with lighter vehicles, would also reduce greenhouse gas and other emissions by 10 percent to 20 percent. 

All of this would come with no sacrifice in safety, as preliminary results of computer crash simulations show that cars made from carbon fiber would be just as safe - perhaps even safer - than today's automobiles. Today's Formula 1 racecars are required to be made from carbon fiber to meet safety requirements. 

Another focus is on developing an efficient carbon fiber oxidation process, which would significantly increase production and lower the cost of this raw material. One promising possibility is plasma processing technology to rapidly oxidize precursor fibers. In this area, ORNL is working with Atmospheric Glow Technologies, a high-tech company spun off from UT that has expertise in atmospheric pressure plasma processing. This is a technique to generate and use plasmas in a non-traditional way - in the open atmosphere instead of in a carefully controlled environment such as in inert gases and at very low pressures. 

ORNL is also establishing a modular carbon fiber research pilot line to evaluate these revolutionary new processes on a comparable basis against conventional industrial processes. "The goal is to demonstrate and transfer the technology to producers of carbon fiber, which could be existing carbon fiber producers or perhaps companies in the forest product industries," Norris said. 

Researchers also are working to develop techniques to allow high-volume cost-effective processing of carbon fiber, hybrid glass-carbon fiber and reinforced thermoplastic material forms. In addition, ORNL recently installed an advanced preforming machine that features a robotically actuated arm that chops and sprays fiber and a binder in powder form to create fiber preforms. 

After being set at elevated temperature, the preforms are injected with resin in a mold and consolidated under pressure to create the final part. "The preforming process is the first step in creating polymer composite structural and semistructural auto parts that are lightweight and cost-competitive with metal parts they would replace," Norris said. 

(Source: ORNL)

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