Bulk nanoporous aluminum enables on-demand hydrogen generation from water and supports additional combustion and energy-related applications. Problem: Hydrogen is not yet widely used as a sustainable energy carrier because common production methods are not carbon-free. Hydrogen storage is challenging because hydrogen gas has very low volumetric energy density. On-board storage commonly relies on compressed tanks. Pressurized flammable gas cylinders create safety concerns and drive the need for on-demand, on-site hydrogen generation. Solution: The invention provides bulk nanoporous materials, including bulk nanoporous aluminum, that generate hydrogen when contacted with water. These materials are fabricated through an air-free non-aqueous electrolytic dealloying process that selectively removes sacrificial material from a parent alloy. The same process can recover the sacrificial material for reuse. The disclosed nanoporous aluminum supports hydrogen generation without added catalysts or reaction promoters in the aluminum-water system. Technology Overview: A parent mixture such as an aluminum-magnesium alloy is contacted with an electrolyte and electrodes, and voltage or current is applied to selectively remove the sacrificial component. This process leaves behind a nanoporous structure with interconnected ligaments and open pores. The disclosed materials can include hierarchical pore and ligament structures, with mesoscopic ligaments reported in the 10-20 nm range. This hierarchical porosity facilitates water transport into the bulk material and hydrogen transport out during reaction. Advantages:
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Docket #18-8558