Ford Uses Carbon Fiber Hood to Reduce Vehicle Weight, Increase Fuel Efficiency
October 9, 2012 3:37 PM
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Ford's carbon fiber hood prototype
(Source: Ford Motor Company)
The new carbon fiber hood prototype weighs more than 50 percent less than the standard steel versions, yet is five times as strong as steel
Ford is looking to make its vehicles even more fuel efficient with a new prototype
hood that weighs less than traditional versions.
The Ford European Research Centre partnered with Dow Automotive Systems in the Hightech.NRW research project to develop the carbon fiber hood prototype. Ford also collaborated with the Institute of Automotive Engineering at RWTH Aachen University, Toho Tenax, Composite Impulse, Henkel, IKV (Institute of Plastics Processing) and Evonik.
The new carbon fiber hood prototype weighs more than 50 percent less than the standard steel versions, yet is five times as strong as steel. The carbon fiber is also twice as stiff as steel and will reduce the weight of Ford vehicles by about 750 pounds by the end of the decade.
"It's no secret that
reducing a vehicle's weight
can deliver major benefits for fuel consumption, but a process for fast and affordable production of carbon fibre automotive parts in large numbers has never been available," said Inga Wehmeyer, advanced materials and processes research engineer for Ford European Research Centre. "By partnering with materials experts through the Hightech.NRW research project, Ford is working to develop a solution that supports cost efficient manufacturing of carbon fibre components."
The project started in 2010 and is expected to continue until September 2013. In that time frame, Ford and its partners set out to develop cost effective methods for carbon fiber manufacturing; reduce individual component production times; reduce the amount of finishing work required; meet requirements for painting, and reduce the component weight by at least 50 percent.
"There are two ways to reduce energy use in vehicles," said Paul Mascarenas, Ford chief technical officer and vice president of Research and Innovation. "Improving the conversion efficiency of fuels to motion and reducing the amount of work that powertrains need to do. Ford is tackling the conversion problem primarily through downsizing engines with EcoBoost and electrification while mass reduction and improved aerodynamics are keys to reducing the workload."
So far, the outcome has been a prototype carbon fiber hood that weighs more than 50 percent less than standard steel. The carbon fiber hood was placed in a
at the Composites Europe event in Dusseldorf, Germany. Early testing suggests that it will meet Ford's standards for dent resistance, crash performance and stiffness.
Increasing fuel efficiency is crucial right now, considering the White House finalized the
54.5 MPG Corporate Average Fuel Economy (CAFE) standards
for 2017-2025 model years back in August of this year. The new standards aim to cut oil consumption/dependency, greenhouse gas emissions and encourage green vehicle adoption.
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RE: Cool, but...
10/10/2012 4:23:46 AM
VIS makes very high quality carbon fiber hoods in OEM styles for hundreds of cars for ~$700. A hood for a 2004 Focus costs $610, 2007 Fusion is $740, and a 2012 Cruze for $700.
Seibon makes decent quality carbon fiber hoods in OEM styles for hundreds of cars for ~$400. Older cars like a 99-05 Jetta MK4 are $300 while a Pontiac G6 is $500.
I use both brands on my vehicles (every car and truck I own has a carbon fiber hood, some painted, some not) and the quality is excellent for both. The VIS hoods have thicker UV clearcoat and copy the OEM cowl contour better (perfectly, actually) but the Seibon hoods are great for daily drivers. I even have a set of carbon fiber fenders as well to protect my turbos, dual stage intake actuators, air intake tubes and other things inside/near the fenders (one of my custom pipes cost 5x as much as the fenders so its worth protecting.)
They can be professionally painted to match your OEM color for under $200 just about anywhere unless you have an exotic paint color. Installation of any hood is incredibly easy, usually four bolts. Getting the old hood off is the hardest part because its heavy. Once its off, you pop in some new windshield washer nozzles ($10-$15 bucks a pair at a dealer) and bolt it on which isn't hard when it weighs <10lbs.
my point is
carbon fiber isn't expensive, its substantially cheaper than people think it is. It has the potential to be cheaper than aluminum because its very, VERY easy to manufacture and work with. It's simply the difference of a stamping + lipping/sealing or a molding press + epoxy.
Manufacture adoption of carbon fiber body parts will obviously bring the costs down significantly as well. Many structural body parts will be carbon in 10 years.
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