Aluminum alloys are valued for their light weight and corrosion resistance, making them ideal for use in a low-carbon economy, such as in lightweight cars or tanks for storing green hydrogen. However, their widespread use has been hindered by one major issue: hydrogen embrittlement (HE), which causes cracking and failure when exposed to hydrogen. Traditionally, alloys resistant to hydrogen embrittlement have been relatively soft, limiting their applications in hydrogen-based technologies that require high strength.

Researchers from the Max Planck Institute for Sustainable Materials (MPI-SusMat) in Germany, along with collaborators from China and Japan, have now developed a new alloy design strategy that addresses this problem. Their innovative approach combines high strength with excellent resistance to hydrogen embrittlement, opening the door to safer and more efficient aluminum components for the hydrogen economy. Their findings are published in the journal Nature.

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Dual Nanoprecipitates Trap Hydrogen and Enhance Strength

The breakthrough lies in a sophisticated precipitation technique applied to scandium-enhanced aluminum-magnesium alloys. Through a two-step heat treatment process, the researchers created fine Al3Sc nanoprecipitates, upon which a shell of a complex Al3(Mg,Sc)2 phase forms in-situ. These dual nanoprecipitates serve two critical functions: the Al3(Mg,Sc)2 phase traps hydrogen and improves HE resistance, while the Al3Sc particles provide additional strength.

"Our new design strategy eliminates the typical trade-off between strength and hydrogen resistance," said Professor Baptiste Gault, head of the Atom Probe Tomography group at MPI-SusMat and one of the lead authors. "With this alloy, we achieve both high strength and hydrogen resistance."

The results are impressive: the new alloy shows a 40% increase in strength and a five-fold improvement in hydrogen embrittlement resistance compared to alloys without scandium. The material also achieves a record tensile elongation of up to 7 ppmw under hydrogen exposure, indicating excellent ductility when charged with hydrogen.

Crucial atom probe tomography measurements at MPI-SusMat confirmed the role of the Al3(Mg,Sc)2 phase in hydrogen trapping at the atomic level, offering valuable insights into how the alloy functions on a fundamental scale. Additional experiments, including electron microscopy and simulations, were conducted at partner institutes.

From Lab to Industry

The researchers tested their method across various aluminum alloy systems and demonstrated its scalability using water-cooled copper mold casting and thermomechanical processing techniques, both of which align with industrial standards. This research paves the way for the development of a new generation of aluminum materials designed for the hydrogen-powered future—strong, safe, and ready for industrial use.