Katerina Swanson
Automakers have been working on improving fuel efficiency for decades, but could they be doing more? American car companies are currently lagging behind foreign competitors, and while there have been record gains in fuel efficiency, it's still not enough to meet fast-approaching deadlines. So, what are the options for automakers to improve fuel efficiency? Well, there are a few things already in motion, such as the creation of new types of steel, the use of lightweight materials, improvements to aerodynamics, and the exploration of alternative fuel sources. However, the auto industry is facing increasing pressure to meet stricter fuel efficiency standards, and it remains to be seen whether they can rise to the challenge and make significant improvements in the coming years.
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What You'll Learn
Lighter and stronger materials
Lighter cars use less fuel, so automakers are increasingly using lightweight materials such as aluminium and other lightweight resources for car parts. The manufacturing industry is working to lower the cost of these materials.
The use of steel in cars has evolved over the past 60 years, with steelmakers creating a vast variety of steels to match every need. For example, there are high-strength, hardened steels for chassis, corrosion-resistant stainless steels for side panels and roofs, and highly stretchable metals in bumpers to absorb impacts without crumpling.
The properties of steel are about microstructure: the arrangement of different types, or phases, of steel in the metal. Some phases are harder, while others are more ductile, a measure of how much the metal can be bent and twisted out of shape without shearing and creating jagged edges. At the atomic level, there are principally four phases of auto steel, including the hardest yet most brittle, called martensite, and the more ductile austenite. Carmakers can vary these by manipulating the times and temperatures of the heating process to produce the properties they want.
Three generations of advanced high-strength steel have been developed. The first, adopted in the 1990s and still widely employed, had a good combination of strength and ductility.
In addition to steel, the use of plastic in cars has increased because it is cheap to make and has a high strength-to-weight ratio, making it ideal for automakers trying to save on weight.
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Alternative fuel sources
The use of alternative fuels in vehicles helps the United States cut oil consumption, improve efficiency, reduce costs, and lower emissions. There are over a dozen alternative fuels in production or development, with government and private-sector fleets being the primary users. However, individual consumers are increasingly interested in these alternative fuels. Here are some examples of alternative fuels:
Biodiesel
Biodiesel is a renewable fuel that can be produced from vegetable oils, animal fats, or recycled cooking grease for use in diesel vehicles.
Electricity
Electricity can power electric vehicles, including all-electric and plug-in hybrid electric vehicles.
Ethanol
Ethanol is a widely used renewable fuel made from corn and other plant materials. It is blended with gasoline for use in vehicles.
Hydrogen
Hydrogen cars use hydrogen as their primary power source, either through combustion or fuel-cell conversion. During combustion, hydrogen is "burned" in engines similarly to traditional gasoline cars. However, the most efficient use of hydrogen involves fuel cells and electric motors, where hydrogen reacts with oxygen to produce electricity to power the motors, with water as the only byproduct.
Ammonia
Ammonia has been proposed as an alternative to fossil fuels for internal combustion engines. While it is less powerful than other fuels, it produces no soot and has a density similar to liquid oxygen, simplifying engine design.
Hybrid Vehicles
Hybrid vehicles use multiple propulsion systems, typically combining gasoline and electric batteries to power internal-combustion engines and electric motors. These vehicles can provide a normal driving experience and are widely available, with over 50 models of hybrid electric cars on the market globally.
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Improved engine design
The improvement of engine design is a key area of focus for automakers seeking to enhance the fuel efficiency of their vehicles. One notable example is the development of hybrid engines, which combine an electric motor with a traditional gasoline engine, resulting in higher fuel economy without the range anxiety associated with purely electric vehicles. The Toyota Prius remains the top-selling hybrid car in America, showcasing the practicality and appeal of this engine design.
Another significant advancement in engine design is the introduction of direct injection technology. Unlike traditional fuel injection, direct injection sprays fuel directly into the combustion chamber, allowing for a leaner and more efficient fuel mix. This technology not only improves fuel economy but also enhances engine power. However, it is relatively new to the market, and the increased complexity of these systems can make repairs more costly.
Engineers have also explored the use of spinning gases within the fuel combustion chamber to increase engine efficiency. This innovative design, proposed by Princeton Professor Nathaniel Fisch and graduate student Vasily Geyko, increases the compressibility of the fuel and enhances the transfer of chemical energy to motion. By utilising the phenomenon of rotation-dependent heat capacity, this approach can lead to a meaningful improvement in engine efficiency, particularly during cold starts, contributing to reduced emissions.
Furthermore, automakers have made strides in engine design by optimising fuel consumption through various technologies. For instance, Jacobs Vehicle Systems has introduced Cylinder Deactivation (CDA) technology, which allows large engines to operate with improved fuel economy akin to smaller engines. This system also enhances exhaust thermal management, benefiting the overall efficiency of the vehicle.
In addition to these advancements, engine oils have become increasingly lighter and lower in viscosity. This transition is due to a combination of tightening emissions standards, improved engine designs, and advancements in petrochemical sciences. By using thinner oils, engines can reduce friction and improve fuel efficiency, as less energy is required to move the oil during lubrication.
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Lower viscosity oils
Switching to a manufacturer-approved lower-viscosity heavy-duty engine oil can reduce fuel consumption by 0.9-2.2% per year. This is a significant saving, and when multiplied across an entire fleet of vehicles, can considerably improve a company's bottom line. For example, a 2% fuel economy improvement from engine oil adjustments translates to cost savings of approximately $919 per year for an average Class 8 truck.
The use of lower viscosity oils is made possible by improvements in engine technology and petrochemical sciences. Today's engines are produced with high-tech machining practices that create surfaces with fewer microscopic peaks and valleys, which allow for the use of thinner oils. This is also driven by tightening emissions standards and other auto regulations, which have pushed automakers to find ways to improve efficiency and add another mile-per-gallon.
It is important to note that the oil must be viscous enough to maintain the separation of critical engine parts while also being thin enough to allow for fuel-efficient powering of the engine. Engine health and oil filter monitoring are crucial during trials of new motor oil viscosity grades to ensure that reducing fuel consumption does not come at the expense of reducing engine protection.
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Aerodynamic testing
Improving the fuel efficiency of their vehicles is an ongoing challenge for automakers. While they have made significant strides in this area, they continue to face increasing demands for more fuel-efficient cars. One of the critical aspects of enhancing fuel efficiency is aerodynamic testing, which plays a pivotal role in reducing drag and optimising vehicle design.
General Motors (GM), for instance, has utilised its wind tunnel to great effect, achieving a notable 25% improvement in vehicle aerodynamics. This has not only enhanced fuel efficiency but also helped reduce wind noise and improve engine cooling systems and HVAC inlets. The testing enabled the development of the Active Grill Opening feature in the 2011 Chevrolet Cruze Eco. By incorporating louvers that respond to vehicle speed and cooling needs, GM achieved a 10% reduction in the drag coefficient, further boosting fuel economy.
Moreover, the use of advanced materials, such as lightweight aluminium and other resources, plays a significant role in enhancing aerodynamics and fuel efficiency. By reducing the overall weight of the vehicle, automakers can further decrease fuel consumption, as lighter cars inherently require less fuel to operate. This multifaceted approach, combining aerodynamic testing, advanced materials, and innovative production processes, underscores the industry's commitment to improving fuel efficiency.
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Frequently asked questions
Automakers can improve fuel efficiency by using lighter materials, such as aluminium and other lightweight resources, for car parts. They can also make small changes to tires, use low-friction lubricants, and make minor aerodynamic changes to car designs.
In 2011, GM improved vehicle aerodynamics by 25% by testing vehicles in a wind tunnel, resulting in a 10% reduction in the drag coefficient and an increase in fuel economy. They have also developed the "Active Grill Opening", which assists in the aerodynamic qualities of the car.
Automakers are exploring alternative fuel sources such as natural gas, ethanol, and liquefied petroleum gas. They are also developing electric vehicles, such as the Tesla Roadster, Chevrolet Volt, and Nissan Leaf.
Steelmakers have created a variety of steels with different properties to match the specific needs of carmakers. For example, high-strength steels are used for the chassis, while corrosion-resistant stainless steels are used for side panels and roofs. By using stronger and lighter steel, cars require less fuel to move.
