Hydrogenation properties and mechanical stability of pellets made starting from compressed ball-milled MgH2 powders mixed with catalysts (Nb2O5 and graphite) and a binding agent (aluminium powder) have been investigated. Structural characterization with X-ray diffraction and gas–solid reaction kinetic and thermodynamic tests with a Sievert's apparatus have been done on the samples up to 50 hydrogen absorption/desorption (a/d) cycles. The best cycling behaviour and mechanical strength stability have been observed for pellets of catalysed MgH2 powders added with 5 wt% aluminium annealed in vacuum at 450 °C before starting the a/d cycles. This mechanical stability to cycles has been attributed to the formation of a solid solution of aluminium in magnesium.
