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This study explores the synthesis of AZ61 alloy composite powders with Co-Ni additives using high-energy ball milling (HEBM). The powders are extensively characterized using scanning electron microscopy (SEM), X-ray diffraction (XRD), and X-ray photoelectron spectroscopy (XPS) to analyze their morphology, composition, structure, and bonding. The hydrogen storage capacity of the powders is measured using a Sievert's-type system revealing diverse capacities. For AZ61 alloy with Ni additive (2 µm), it absorbs 90% of the capacity in 410 s, showing an activation energy of 91.46 kJmol−1 and displays Mg 2 NiH 4 as an intermediate. On the other hand, AZ61 alloy with Co additive requires 576 s to absorb 90% of the capacity, showing an activation energy of 117.23 kJmol−1 and Mg 2 CoH 5 as an intermediate. When a mixture of Ni and Co is added to AZ61 alloy, it achieves 90% capacity absorption in 300 s. In the absence of additives, AZ61 alloy (15 µm) reaches 90% capacity absorption in 1600 s. The incorporation of additives significantly reduces the activation energy. A correlation between longer absorption times and larger activation energies provides valuable insights into the storage kinetics and activation energy associated with the hydrogen absorption/desorption process. [Display omitted] • The addition of Ni, Co, and a mixture of Ni and Co to the AZ61 alloy enhances its hydrogen storage capacity compared to the alloy without additives. • The hydrogen storage capacities of the AZ61 alloy with Ni, Co, and Ni-Co additives were measured to be 4.5 wt%, 5.316 wt%, and 5.14 wt%, respectively. • The presence of specific reaction intermediates, such as Mg 2 NiH 4 and Mg 2 CoH 5 , was confirmed through XRD patterns, indicating their role in the hydrogen absorption process and promoting reversibility and cycle stability. • The activation energy for hydrogen absorption in the AZ61 alloy with Co additive was found to be 117.23 kJ/mol while that of Ni was 91.46 kJ/mol. • Kinetics to achieve 90% capacity: AZ61 alloy with Ni additive requiring 410 s, the alloy with Co additive requiring 576 s, the alloy with Ni and Co mixture requiring 300 s, and the alloy without additives requiring 1600 s. These results highlight the influence of additive composition on the kinetics of hydrogen absorption. [ABSTRACT FROM AUTHOR]

We studied the hydrogen storage properties of commercial AZ31 and AZ91 magnesium alloys with refined microstructure. Various processing techniques, such as equal channel angular pressing (ECAP) and high energy ball milling (HEBM), were utilized to modify the microstructure and phase composition of the alloys. X-ray diffraction (XRD), scanning electron microscopy (SEM), and optical digital microscopy (ODM) were utilized to characterise the microstructure and phase transformations during the hydrogen absorption/desorption processes. The isothermal kinetics are measured by a Sieverts'-type apparatus at the temperature of 350 ℃. In the ECAP process, the AZ31 alloy had a slightly higher storage capacity and faster absorption kinetics, absorbing 6.0 wt% (6.6 wt% - maximum) of hydrogen in less than 12 min. In the HEBM process, AZ91 absorbed 6.5 wt% of hydrogen and desorbed it in 347 ± 13 s, a faster rate than AZ31. The pressure–composition isotherms of all studied alloys at a temperature of 300 °C were determined. The processed alloys exhibited no pressure hysteresis. The microstructure of bulk samples and the morphology of prepared powders were shown to affect their hydrogenation behaviour. The activation energies for hydrogen desorption were 119 ± 2 kJ/mol for AZ31 alloy processed by ECAP and 128 ± 3 kJ/mol for AZ91 alloy processed by HEBM, which are significantly lower than the activation energy values of pure Mg hydride. • Hydrogen storage properties of commercial AZ31 and AZ91 alloys are studied. • The ECAP and HEBM processes were employed to enhance hydrogen storage performance. • Both processes significantly improved the kinetic and thermodynamics properties. • The processed alloys exhibited no pressure hysteresis • The activation energies reduced to 119 ± 5 kJ/mol for AZ31-ECAP and 128 ± 5 kJ/mol for AZ91-HEBM. [ABSTRACT FROM AUTHOR]