Research reveals how iron and nickel can reduce the costs of green hydrogen production, accelerating advances in clean energy and sustainable innovation.
The Brazilian researchers associated with the Center for the Development of Functional Materials (CDMF) participated in research that may help reduce one of the main challenges of the hydrogen economy. Published in Science Direct on February 25, 2026, the study shows that the controlled combination of iron and nickel can result in an efficient and cheaper catalyst for the production of green hydrogen.
The research was conducted by scientists linked to the CDMF, a Research, Innovation, and Dissemination Center (CEPID) funded by FAPESP and based at the Federal University of São Carlos (UFSCar). The results indicate that the use of abundant metals can replace noble and expensive materials, such as platinum, expanding the potential of clean energy on a global scale.
The work also reinforces the importance of computational modeling to accelerate the discovery of new materials and make technological development more efficient.
Brazilian study points the way to make green hydrogen cheaper
The production of green hydrogen is considered one of the most promising alternatives to reduce carbon emissions in industrial sectors, transportation, and energy generation. However, the costs involved still represent an obstacle to the expansion of this technology.
A large part of this challenge is related to the materials used in water electrolysis systems. Currently, the most efficient catalysts are produced with noble metals, especially platinum, which has a high market value and limited availability.
It was precisely this barrier that motivated the Brazilian researchers to investigate new combinations of abundant metals, capable of offering similar performance at a much lower cost.
The main focus of the research was to understand how the interaction between hydrogen and the surface of certain materials influences the efficiency of the chemical reaction. In this process, the catalyst acts as a facilitator. It helps hydrogen atoms to unite and detach from water in the form of gas, a phenomenon known as the hydrogen evolution reaction.
According to the study results, the proper combination of chemical elements allows precise control of the strength of this interaction. This balance is considered fundamental to accelerate the reaction and increase the efficiency of green hydrogen production. Scientists discovered that small changes in the composition of the metal alloy can significantly modify the material’s behavior, making the process more predictable and efficient.
To find alternatives to platinum, the Brazilian researchers analyzed different alloys formed by abundant metals. The goal was to verify if more accessible materials could reproduce the characteristics observed in noble metal-based catalysts.
The simulations indicated that certain chemical combinations have very promising properties. Among them, the alloy formed by iron and nickel stood out for its ability to control the adsorption of hydrogen on the material’s surface.
This phenomenon is considered one of the main indicators of a catalyst’s efficiency, as it directly influences the speed of the chemical reaction.
The iron and nickel alloy that caught the scientists’ attention
Among all the combinations evaluated, the iron and nickel alloy presented the most relevant results.
According to the authors, the interaction between the two elements works as a kind of fine-tuning. By altering the proportion of iron and nickel, it is possible to control exactly the intensity with which hydrogen attaches to the material’s surface.
This characteristic offers an important advantage for the development of new systems aimed at green hydrogen. Besides using abundant metals, the technology can facilitate the creation of more efficient and potentially cheaper materials for future industrial applications.
Computational simulations accelerate the discovery of new materials
Another important aspect of the research was the use of advanced computational modeling. Instead of producing numerous samples in the laboratory, scientists used simulations to predict the behavior of materials even before their physical synthesis. This approach is known as rational material design and is gaining prominence in various areas of science.
Among the main advantages of this method are:
- Reduction of research time;
- Lower consumption of financial resources;
- Greater precision in the selection of materials;
- Acceleration of technological development;
- Quick identification of promising combinations.
According to the authors, this strategy can significantly contribute to the advancement of technologies related to clean energy.
Why green hydrogen is strategic for the energy transition
The global interest in green hydrogen has been rapidly growing in recent years. Unlike conventional hydrogen, produced from fossil fuels, this version is obtained through water electrolysis using electricity from renewable sources.
The result is a fuel that can be used in various sectors without generating direct carbon dioxide emissions during use. International organizations and governments of different countries see this technology as an important tool to achieve climate neutrality goals and expand the use of clean energy.
The sectors that can benefit include:
- Steel industry;
- Fertilizer production;
- Maritime transport;
- Aviation;
- Energy storage;
- Electric power generation.
The use of abundant metals can bring benefits that go beyond simple cost reduction. These materials are available in much larger quantities than noble metals, facilitating the expansion of industrial production and reducing risks associated with the supply of raw materials.
Furthermore, the greater availability of these elements favors the creation of more stable and resilient production chains. Among the main benefits identified by experts are:
- Less dependence on rare metals;
- Potentially lower costs;
- Greater industrial scalability;
- Ease of obtaining raw materials;
- Increased competitiveness of green hydrogen.
These characteristics make the development of a new catalyst based on iron and nickel especially relevant for the future of the energy sector.
The role of CDMF and UFSCar in national research
The study involved scientists affiliated with the Center for the Development of Functional Materials (CDMF), one of the main Brazilian centers dedicated to research on new materials.
CDMF is part of the FAPESP CEPID program and is based at the Federal University of São Carlos (UFSCar), an institution recognized for scientific production in strategic areas for technological development.
The involvement of Brazilian researchers in this type of investigation demonstrates the capacity of national science to contribute to global challenges related to sustainability, innovation, and energy transition.
What this advancement could mean for the future of clean energy
The results published in the scientific article Tuning hydrogen adsorption through synergy in non-noble bimetallic substrates provide an important theoretical guide for the development of new materials aimed at the production of green hydrogen.
By demonstrating that a catalyst based on abundant metals can present highly promising characteristics, the research paves the way for more accessible and scalable technologies. Although further experimental steps are still necessary, the discovery reinforces the potential of computational modeling and rational material design to accelerate strategic innovations.
If the results are confirmed in practical applications, Brazilian researchers could directly contribute to making clean energy more competitive, expanding the use of green hydrogen and strengthening the transition to a low-carbon economy in various regions of the world.
With information from Science Direct.
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