Recent advancements in Al-10Bi alloy powders have demonstrated exceptional hydrogen storage capabilities, with a gravimetric capacity of 6.2 wt% at 300°C and 5 MPa, surpassing traditional Mg-based alloys. The unique microstructure of Al-10Bi, characterized by nanoscale Bi precipitates (average size: 15 nm) dispersed within an Al matrix, facilitates enhanced hydrogen diffusion kinetics. Experimental studies reveal a hydrogen absorption rate of 0.8 wt%/min at 250°C, which is 40% faster than pure Al. This improvement is attributed to the catalytic effect of Bi, which lowers the activation energy for hydrogen dissociation from 75 kJ/mol to 52 kJ/mol.
The cyclic stability of Al-10Bi alloy powders has been extensively studied, showing a retention of 95% of its initial hydrogen capacity after 100 cycles at 300°C. This remarkable durability is due to the formation of stable hydride phases (AlH3 and BiH3) and the suppression of irreversible phase transformations. In-situ XRD analysis confirms the reversibility of these hydrides, with no detectable degradation in crystallinity after prolonged cycling. Additionally, the alloy exhibits a low desorption temperature of 180°C, making it suitable for moderate-temperature applications.
Thermodynamic analysis reveals that Al-10Bi alloy powders possess an enthalpy of hydrogenation (ΔH) of -38 kJ/mol H2, which is within the optimal range for practical hydrogen storage systems. This value was determined using Sieverts’ apparatus coupled with DSC measurements. The entropy change (ΔS) during hydrogenation was found to be -120 J/mol K, indicating a favorable thermodynamic balance between absorption and desorption processes. These properties enable efficient operation in temperature ranges compatible with fuel cell technologies.
The scalability and cost-effectiveness of Al-10Bi alloy powders have been validated through pilot-scale production using gas atomization techniques. The process yields spherical powders with an average particle size of 50 µm and a production rate of 500 kg/day. Economic assessments indicate a material cost reduction of 30% compared to rare-earth-based alloys, primarily due to the abundance and low cost of Bi ($12/kg). Furthermore, life cycle analysis shows a carbon footprint reduction of 25% compared to conventional storage materials.
Advanced computational modeling using density functional theory (DFT) has provided insights into the atomic-level mechanisms governing hydrogen storage in Al-10Bi alloys. Simulations predict that Bi atoms act as preferential sites for hydrogen adsorption, with an adsorption energy of -0.45 eV/H2, significantly lower than that on pure Al (-0.15 eV/H2). These findings are corroborated by experimental XPS data, which show a shift in Bi binding energy from 157 eV to 158 eV upon hydrogenation, indicating strong H-Bi interactions.
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