Mg-xCa (x = 3, 7, 11, 14, wt.%) binary hypoeutectic alloys are successfully synthesized via solidification in the present work. The microstructure, phase compositions and hydrogen generation characteristics of as-cast Mg–Ca alloys and ball milled Mg–Ca composites with TiC and Ni addition have been investigated in this work for a new hydrogen supply source application. A lamellar structure with alternately distributed Mg and Mg2Ca is formed in the eutectic regions of as-cast Mg–Ca binary alloys. It is found that as-cast Mg–Ca binary alloys show extremely sluggish hydrolysis kinetics and low hydrogen yield in both tap water and simulated seawater. Mg2Ca phase preferentially reacts with water during hydrolysis process in simulated seawater. Many cracks arise with hydrolysis reaction, meanwhile, the cracks further assist in the hydrolysis of the internal matrix via assisting water solution transfer. After ball milling with TiC and Ni of Mg–Ca binary alloys, the hydrolysis performance is substantially modified. Mg–14Ca-3wt.%TiC-5wt.%Ni composite generates 836.6 mL g−1 of hydrogen within initial 95 min. The conversion rate of Mg–14Ca-3wt.%TiC-5wt.%Ni composite in simulated seawater is as high as 99.4%, indicating a thorough hydrolysis of Mg and Mg2Ca phases with the catalysis of TiC and Ni. This work shows that microstructure refinement, catalysis, Mg(OH)2 exfoliation and water solution transfer account for the complete hydrolysis.
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