Palladium-based membranes for hydrogen separation offer the most promising gas permeation and selectivity, but their large-scale application has been limited due to the high environmental burdens and criticality of palladium. Herein, the possibility of substituting Pd with candidate elements in the composition of metallic micro-scale membranes (with permeability in the range of 5–50 × 10⁻¹² mol m^–1 Pa^–1 s⁻¹) deposited via High Power Impulse Magnetron Sputtering was investigated. This study proposed an innovative framework for a more comprehensive investigation of the sustainability challenges related to this lab-scale technology by integrating Life Cycle Assessment (LCA) and criticality analyses, thereby supporting materials selection efforts. First, the criticality status of several elements used in hydrogen separation membranes was screened with two different approaches. Furthermore, the environmental impacts of novel membrane compositions were compared with a high Pd-content reference membrane (Pd₇₇Ag₂₃) through cradle-to-gate LCA. For robust LCA modeling, uncertainty analysis was performed via Monte Carlo simulation, exploiting errors estimated for both primary and secondary data. A direct relationship was identified between the Pd content in membranes and the associated environmental impacts. VPd proved to be a promising candidate by exhibiting lower total impacts than the PdAg (65% or 71% considering thickness of 3.16 µm or permeance of 2.03 × 10⁻⁶ mol m⁻² Pa⁻¹ s⁻¹, respectively).

Low-Energy High-Current Electron Beam (LEHCEB) is an innovative vacuum technology employed for the surface modification of conductive materials. Surface treatments by means of LEHCEB allow the melting and rapid solidification of a thin layer (up to ~10 μm) of material. The short duration of each pulse (2.5 μs) allows for the generation of high thermal rates, up to 10⁹ K/s. Due to the peculiar features of LEHCEB source, in situ temperature monitoring inside the vacuum chamber is unfeasible, even with the most rapid IR pyrometers available on the market. Therefore, multiphysics simulations serve as a tool for predicting and assessing the thermal effects induced by electron beam irradiation. COMSOL Multiphysics was employed to study the thermal behaviour of metals and alloys at the sub-microsecond time scale by implementing both experimental power time profiles and semi-empirical electron penetration functions. Three case studies were considered: (a) 17-4 PH steel produced by Binder Jetting, (b) biphasic Al-Si13 alloy, and (c) Magnetron Sputtering Nb films on Ti substrate. The influence on the thermal effects of electron accelerating voltage and number of pulses was investigated, as well as the role of the physicochemical properties of the materials.

CoCrMo alloys are interesting materials for implantable devices due to their favorable mechanical properties, high wear resistance, and good biocompatibility with the human body. Recent studies have demonstrated the possibility to further increase their wear resistance with an innovative approach consisting of nitriding treatments by the High-Power Impulse Magnetron Sputtering (HiPIMS) technique. Given the novelty of this treatment, it is relevant to develop a preliminary sustainability analysis of the processes to highlight the total environmental impact and to evaluate possible strategies to decrease it. Here, a Life Cycle Assessment (LCA) of HiPIMS nitriding treatments of CoCrMo alloys using a tantalum or molybdenum target is presented. The main impact driver in all impact categories was the electrical consumption of the vacuum apparatus and cooling system of HiPIMS instrumentation with a 45–47% and 37–39% contribution for Ta-based, and 39–40% and 41–42% for Mo-based treatments, respectively. Climate Change was found to be the most impacted category, followed by Resource Use both for Mo and Ta nitriding targets. Therefore, some perspectives to enhance the environmental sustainability of the synthesis process have been considered by means of a sensitivity analysis. Moreover, a Critical Raw Material (CRM) assessment is discussed, providing a complete sustainability evaluation of the proposed HiPIMS treatments.

Palladium-based membranes for hydrogen separation offer the most promising gas permeation and selectivity, but their large-scale application has been limited due to the high environmental burdens and criticality of palladium. Herein, the possibility of substituting Pd with candidate elements in the composition of metallic membranes deposited via High Power Impulse Magnetron Sputtering (HiPIMS) was investigated. This study proposed an innovative framework for a more comprehensive investigation of the sustainability challenges related to this lab-scale technology by integrating LCA and criticality analyses, thereby supporting materials selection efforts. First, the criticality status of several elements used in hydrogen separation membranes was screened with two different approaches. Furthermore, the environmental impacts of novel membrane compositions were compared with a high Pd-content reference membrane (Pd77Ag23) through cradle-to-gate Life Cycle Assessment (LCA). For robust LCA modeling, uncertainty analysis was performed via Monte Carlo simulation exploiting errors estimated for primary data. A direct relationship was identified between the Pd content in membranes and the associated environmental impacts. VPd membranes proved to be the most promising candidate by exhibiting 65% lower total impacts than the PdAg membrane while maintaining a high hydrogen permeability performance.