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Abstract Global attention is increasingly focused on recycling and clean energy generation. The present study delves into both areas by examining the reuse of secondary aluminium for hydrogen generation. The aim is to investigate how the microstructural length scale influences the hydrogen production behaviour of two Al-3%Mg (wt.%) alloys, with and without a 10% Sn addition. Al-3%Mg serves as base for commercial alloys like 5056, 5154, and 5754. Additionally, since Sn is normally used as a solid lubricant for bearings, the analysis also extends to Sn-containing Al-Mg alloys, which can be repurposed for clean energy generation, after the end of their life service. Solidified samples with varying microstructural length scales underwent hydrogen evolution tests in a 1 M NaOH solution. While the binary alloy shows no sensitivity with respect to the microstructural length scale in hydrogen production rate, Sn not only exhibits sensitivity but also boosts it by approximately 350 % when both alloys are compared.
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