Extra-Strong Aluminum Alloys Developed for the Hydrogen Economy
The new alloy has a 5x higher resistance to hydrogen embrittlement and 40% higher strength, while maintaining the same ductility.
Complete the form below to unlock access to ALL audio articles.
To the point
- Novel alloy design for aluminum: Researchers mix scandium with aluminum alloys to achieve 40 percent higher strength and five times higher resistance to hydrogen embrittlement - while maintaining the same ductility.
- Tuning the microstructure: Nanoparticles with a shell of particles out of aluminum, magnesium and scandium trap hydrogen and reduce the risk of embrittlement, while nanoparticles of aluminum and scandium increase strength.
- Industrial applicability: The strong and hydrogen-resistant alloys have already been produced under almost industrial conditions.
Aluminum alloys are well-known for their low weight and corrosion resistance, making them ideal candidates for applications in a low-carbon economy - from lightweight automobiles to tanks for storing green hydrogen. However, their widespread application is limited by a key challenge: they suffer from embrittlement leading to cracking and failure when exposed to hydrogen. Till now, alloys resistant to hydrogen embrittlement were rather soft, limiting their application in hydrogen-related technologies that require high strength.
Now, researchers from the Max Planck Institute for Sustainable Materials in Germany, together with partners from China and Japan, have developed a new alloy design strategy that overcomes this dilemma. Their approach enables both exceptional strength and superior resistance to hydrogen embrittlement, paving the way for safer and more efficient aluminum components in the hydrogen economy. They have published their results in the journal Nature.
Dual nanoprecipitates trap hydrogen and boost strength
At the heart of the breakthrough is a complex, size-sieved precipitation strategy in scandium-added aluminum-magnesium alloys. Through a two-step heat treatment, the researchers engineered fine Al3Sc nanoprecipitates on which a shell of a highly structurally complex Al3(Mg,Sc)2 forms in-situ. These dual nanoprecipitates are distributed throughout the alloy to serve two key roles: the Al3(Mg,Sc)2 phase traps hydrogen and enhances resistance against hydrogen embrittlement, while the fine Al3Sc particles boost strength.
“Our new design strategy solves this typical trade-off. We no longer have to choose between high strength and hydrogen resistance - this alloy delivers both”, says Baptiste Gault, group leader at the Max Planck Institute for Sustainable Materials.
The results are compelling: a 40 percent increase in strength and a five-fold improvement in hydrogen embrittlement resistance compared to scandium-free alloys. The material even achieves a record uniform tensile elongation in hydrogen-charged aluminum alloys at even relatively high hydrogen loading - an indicator of excellent ductility under hydrogen exposure. Atom probe tomography measurements carried out at the Max Planck Institute for Sustainable Materials were essential in verifying the role of the Al3(Mg,Sc)2 phase in hydrogen trapping at the atomic level, offering insights into how the alloy design works on a fundamental scale. Experiments carried out at the partner institutes included electron microscopy and simulation.
From lab to industry
The researchers tested their approach across various Al alloy systems, and also demonstrated scalability by using water-cooled copper mould casting and thermomechanical processing methods that align with current industrial standards. This research lays the groundwork for a new generation of aluminum materials tailored for the demands of a hydrogen-powered future – safe, strong, and ready for industrial use.
Reference: Jiang S, Xu Y, Wang R, et al. Structurally complex phase engineering enables hydrogen-tolerant Al alloys. Nature. 2025;641(8062):358-364. doi: 10.1038/s41586-025-08879-2
This article has been republished from the following materials. Note: material may have been edited for length and content. For further information, please contact the cited source. Our press release publishing policy can be accessed here.
