In this study, a novel self-assembling hydrogen generation powder comprised of 80Al-10Bi-10Sn wt.% was prepared using the gas atomization method and then collected in an air environment. The morphological and hydrolysis properties of the powders were investigated. The results indicated that the powders formed unique core/shell microstructures with cracked surfaces and (Bi, Sn)-rich phases distributed on the Al grain boundaries. The powders exhibited good oxidation resistance and reacted violently with distilled water at temperatures as low as 0 °C. Furthermore, at 30 °C, the powders exhibited a hydrogen conversion yield of 91.30% within 16 minutes. The hydrogen produced by this powder could be directly used in proton exchange membrane fuel cells. The mechanisms of the hydrolysis reactions were also analyzed.
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