ZrCo alloy is easily poisoned by impurity gases such as O₂, CO, and CO₂, resulting in a deterioration in hydrogen storage performance. In this study, we conducted a comprehensive investigation into the adsorption and dissociation characteristics of oxygen on the ZrCo(110) surface using first-principles calculations. Previous studies indicated that the anti-disproportionation properties of ZrCo alloy can be significantly improved by Hf substitution, but the effect of Hf doping on the anti-poisoning properties has not been reported. We also examined the effect of Hf doping on the adsorption, dissociation, and diffusion characteristics of oxygen. It is found that on the ZrCo(110) surface, O₂ molecules are easily dissociated and then stably adsorbed at the hollow site. Oxygen atoms will fill the surface preferentially and then diffuse inward. The doping of Hf has an insignificant impact on the adsorption or dissociation behavior of oxygen in comparison to the pure ZrCo surface. However, a notable observation is that the doping of Hf resulted in a reduction in the diffusion barrier for oxygen from the surface to the subsurface by 0.61 eV. Consequently, our study suggests that doping Hf is not an advisable strategy for improving the ZrCo(110) surface’s resistance to O₂ poisoning because of improved oxygen permeability.

In order to enhance the hydrogen absorption performance and poisoning resistance of ZrCo to O₂, Pd/ZrCo composite films were prepared by direct current magnetron sputtering. The results show that the initial hydrogen absorption rate of the Pd/ZrCo composite film increased significantly due to the catalytic effect of Pd compared with the ZrCo film. In addition, the hydrogen absorption properties of Pd/ZrCo and ZrCo were tested in poisoned hydrogen mixed with 1000 ppm O₂ at 10–300 °C, where the Pd/ZrCo films maintained a better resistance to O₂ poisoning below 100 °C. The mechanism of poisoning was investigated jointly by first-principles calculation combined with SEM-EDS elemental mapping tests. It is shown that the poisoned Pd layer maintained the ability to promote the decomposition of H₂ into hydrogen atoms and their rapid transfer to ZrCo.