Nickel mesh is used as an electrode or electrode support in alkaline water electrolysis. Its metal network carries current, while the openings provide space for electrolyte movement and gas release. The material’s role depends on the cell design and on whether the nickel surface is used directly or carries an additional catalyst layer.
Mesh structure is part of this design. Wire diameter, opening size, thickness and the form of the mesh all help describe the component placed in the cell.
The role of nickel in an alkaline electrode
In an electrolyzer, the electrode connects the electrical circuit with the reaction occurring at its surface. A mesh can provide a conducting framework and a surface on which a catalytic layer is formed. The performance of that finished electrode depends on its surface chemistry as well as its supporting structure.
A published result for a coated or activated nickel electrode describes that complete preparation and test. It should be read with the treatment and operating conditions attached to it. This keeps the properties of the starting mesh separate from the measured performance of the finished electrode.
Woven, expanded and knitted structures
Woven nickel mesh is made from interlaced wires. Wire diameter and aperture help describe the open pathways and metal framework. Expanded mesh is formed from a cut and expanded sheet, so strand width, sheet thickness and opening geometry are the relevant descriptors.
Researchers have compared both woven and expanded nickel meshes for alkaline hydrogen evolution. A 2021 experimental study found that structural features, including strand width and opening width, affected the measured response. The result supports comparing the actual geometry rather than choosing by the word “mesh” alone.
Knitted nickel mesh uses interlocking loops and is also offered by HuiRui for electrolytic-cell support enquiries. Its construction should be described separately from a woven sheet. A woven-mesh count does not fully specify a knitted support.
Openings and bubble release work together
Gas bubbles form during hydrogen and oxygen evolution. Their interaction with the electrode surface is one reason that open area alone does not establish which mesh will perform best.
A 2025 study of nickel wire mesh cathodes examined mesh geometry together with hydrogen-bubble departure. Changing the alkaline electrolyte concentration changed the performance ranking of the meshes. The practical lesson is that an apparently favourable structure in one experiment may behave differently under another set of operating conditions.
For a meaningful comparison, the electrolyte, temperature, current-density basis and surface preparation belong alongside the mesh description. This is especially useful when reading research papers or comparing results from different test cells.
Choose the form for the component’s role
A flat woven electrode, a knitted support and a three-dimensional porous electrode are different starting points. Where a project calls for a porous volume, nickel foam or nickel fiber felt may be useful alternatives to explore. The choice follows the component’s intended role in the assembly.
Browse the HuiRui nickel mesh range for current product forms. For help with product information or a quotation, contact HuiRui.