Al6060 cut wire granules for Al-water reaction: Evaluation of reaction conditions and granule treatments

Aluminium (Al) is a promising Renewable Metal Fuel (ReMeF) for seasonal energy storage due to its high abundance and energy density. Most Al-water reaction studies use Al powder for fast kinetics, but its ignition risks pose safety challenges. This article explores using commercially available cut wire Al6060 granules above the explosion size threshold as a cheap, safe and reactive source of Al fuel. Most suitable conditions were defined for reaction in alkaline aqueous media. Importantly, activity data combined with microscopy studies reveal a reaction mechanism characterized by pore formation and fast reaction kinetics. We propose that Al6060 cut wire microstructure directs the corrosive attack towards pore formation making these granules safe and yet highly active under reaction conditions. This work brings new insight into how Al manufacturing could be adjusted to promote faster oxidation rates and produce Al granules suitable for ReMeF applications. • Al is a promising ReMeF for seasonal energy storage with high density and availability. • Al reacts with water to generate heat and H 2. • Al6060 cut wire granules avoid ignition risks of powders and exhibit high reactivity with water. • Fast kinetics are attributed to Al6060 microstructure which leads to formation of pores. • Suitable reaction conditions were defined for Al6060 cut wire granules.