Aluminum scrap is one of the most common materials found on military bases and aircraft carriers worldwide. Now, the U.S. Army has tapped Georgia Tech to help turn that waste into power that can be generated off the grid and on demand. 

The Army Research Office awarded Georgia Tech and its partners $20 million to develop scalable, efficient methods for transforming aluminum into hydrogen energy. The project could lead to a new, low-cost, clean, and efficient energy source powered by discarded materials. 

Aaron Stebner, professor and Eugene C. Gwaltney Jr. Chair in Manufacturing in the George W. Woodruff School of Mechanical Engineering and professor in the School of Materials Science and Engineering, will oversee the multi-year effort at Georgia Tech together with Scott McWhorter, lead for Federal Initiatives at the Strategic Energy Institute.

In addition to several team members from Georgia Tech and the Georgia Tech Research Institute, the project includes researchers from Fort Valley State University, the 21st Century Partnership, MatSys, and Drexel University. 

“Aluminum already reacts with water — even wastewater and floodwater — to create hydrogen gas, power, and thermal energy,” McWhorter said. “If aluminum can be efficiently upcycled into stored energy, it could be a game-changer.” 

The team’s goal is to experiment with aluminum’s material properties so it can be inexpensively manufactured to create a highly effective reaction that produces low-cost, clean hydrogen.

“Having this ability would allow military bases to be less dependent on the use of a foreign country’s electrical grids,” said Stebner, who is also co-director of Georgia Artificial Intelligence in Manufacturing and faculty at the Georgia Tech Manufacturing Institute. 

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