Hydrogen separation membrane devices are attracting increasing interest for the industrial production of
hydrogen. Metal membranes, in particular, are promising due to their resilience to the demands of a typical
hydrogen purification process. However, the use of too much Pd within the membranes limits their wide-scale industrial use due to excessive costs. The present article reviews the design, preparation, operation, and
critical performance features of novel non-Pd-based alloys. The theory behind the permeation of hydrogen
through metal membranes is presented as well as the materials and methods central to their design and
improvement. Crystalline, amorphous, and thin layer metal membranes are contrasted, while the advanced
experimental techniques and mechanical tests for their characterization are discussed. The review considers
the design of novel metal membranes from first principles and assesses catalytic and protective surface layers
which may enhance their hydrogen separation capabilities.