Porous Nickel Foam 95% Porosity 5mm Electrode ATOMFAIR®

POROUS NICKEL FOAM 95% POROSITY 3D RETICULATED BATTERY ELECTRODE

RESEARCH GRADE MATERIAL

Product Overview

This Porous Nickel Foam is a high-performance functional porous metal material manufactured via an advanced electrodeposition process to achieve a fully interconnected 95% porosity 3D reticulated structure. Retaining the intrinsic physicochemical properties of pure nickel—including excellent electrical conductivity and corrosion resistance—the material achieves an ultra-low bulk density of 0.1–0.8 g/cm³, merely 1/50th that of solid nickel. The open-cell architecture serves as an optimal battery electrode current collector for Ni-MH, Ni-Cd, and lithium-ion systems, where its high specific surface area enhances active material loading and charge transfer kinetics. Engineered as a high temperature corrosion resistant substrate capable of withstanding operating temperatures up to 1100°C, this foam delivers reliable performance across electrochemical, catalytic, and thermal management applications in demanding research and industrial environments.

Technical Specifications

PARAMETER	DETAILS
Material	High-Purity Nickel (Ni)
Thickness Range	1 mm–25 mm (Customizable)
Pore Size Range	0.1 mm–10 mm (5–130 PPI)
Porosity	≥95% (Up to 98%)
Through-Hole Ratio	≥98%
Bulk Density	0.1–0.8 g/cm³
Standard Dimensions	500 × 1000 mm (Custom Available)
Tensile Strength	8–50 MPa (ISO 6892-1:2019)
Compressive Strength	≥250 KPa at 50% Compression (ISO 844:2014)
Mechanical Strength	2–7 MPa
Temperature Resistance	≥500°C (Up to 1100°C)
Thermal Conductivity	>3 W/(m²·K) (ISO 22007-2:2015)
Weaving Method	Knitted
Corrosion Resistance	Acid & Alkali Resistant (ISO 11845:1995)
Color	Gray
Alternative Options	Explore our related catalog or custom dimensions. For urgent technical custom requests or bulk inquiries, please contact our support team.

Key Features & Advantages

Ultra-Lightweight with High Specific Surface Area: With a specific gravity of only 0.2–0.3—approximately 1/4 that of water and 1/30 that of iron—this porous nickel foam achieves 96–98% porosity while delivering an exceptionally large specific surface area critical for catalytic loading and electrochemical active material integration.
Broadband Acoustic Absorption & Damping: The stochastic 3D reticulated structure enables wide-frequency sound absorption via viscous friction and thermal dissipation within the micro-pores, providing significant noise reduction after proper treatment for acoustic isolation and vibration damping applications.
High-Efficiency EMI Shielding: Even thin-section configurations achieve approximately 90 dB electromagnetic interference shielding effectiveness, meeting stringent EMI/EMC requirements for sensitive electronic instrumentation and communications equipment.
Superior Thermal Management & High-Temperature Stability: Exhibiting thermal conductivity exceeding 3 W/(m²·K), the foam functions as an efficient heat spreader and heat pipe wick material. The structure remains flame-retardant and mechanically stable at operating temperatures up to 1100°C.

APPLICATION SCOPE: Validated for use as an electrode current collector in Ni-MH, Ni-Cd, fuel cell, and lithium-ion battery systems, including nickel foam-carbon composite electrodes for enhanced electrochemical performance. Functions as a catalyst carrier in chemical reactors, automotive exhaust purification, and air purification systems. Serves as an oil-water separator medium, distillation column packing, and condenser heat exchange material. Applicable in electrochemical engineering for hydrogen production, electrocatalysis, and electro-metallurgy. Suitable for thermal management in electronic devices, acoustic absorption panels, EMI shielding enclosures, flame-retardant barriers, and high-end decorative architectural materials.

PACKAGING: Standard sheet stock (3 mm thickness, 10 PPI) available for immediate dispatch. Product is supplied as flat sheet, disc, cone, or ring configurations per customer specification. Each unit is vacuum-sealed in low-outgassing polyethylene film and packaged with rigid protective plates to preserve the delicate 3D reticulated structure during transit. Custom dimensions, thicknesses, PPI grades, and geometric shapes are manufactured to order.

IMPORTANT NOTICE: For high-temperature applications exceeding 500°C in oxidizing atmospheres, pre-conditioning of the nickel foam in a reducing environment (H₂/Ar) is recommended to remove surface oxide layers and restore full electrical conductivity. When handling thin sheets (< 1 mm thickness), utilize vacuum pickup tools to prevent localized plastic deformation of the pore walls. The material is fully recyclable as metallic nickel and complies with international environmental standards. Store in a dry, temperature-controlled environment; while the material is inherently acid-alkali resistant per ISO 11845:1995, prolonged exposure to concentrated oxidizing acids may cause gradual surface passivation.

TAILORED SOLUTIONS FOR RESEARCH

Contact our engineering team for technical support or official quotations.

EMAIL: inquiry@atomfair.com

Manufacturer: Atomfair LLC

Brand: ATOMFAIR®

How does the high porosity of 95% impact the mechanical integrity of porous nickel foam for use as a battery electrode current collector?

The ≥95% porosity (up to 98%) reduces bulk density to 0.1–0.8 g/cm³, but it also limits tensile strength to 2–7 MPa and compressive strength to ≥250 KPa at 50% compression per ISO 844:2014. This trade-off is acceptable for electrode applications where high surface area enhances active material loading and charge transfer, but requires careful handling to avoid plastic deformation during assembly.

What pre-treatment is required when using porous nickel foam at temperatures above 500°C in an oxidizing atmosphere?

For high-temperature applications exceeding 500°C in oxidizing atmospheres, pre-conditioning in a reducing environment (H₂/Ar) is recommended to remove surface oxide layers and restore full electrical conductivity. Without this step, the oxide layer may increase contact resistance and degrade electrochemical performance in battery or catalytic applications.

What are the recommended handling and storage precautions for thin porous nickel foam sheets to avoid damaging the 3D reticulated structure?

For sheets thinner than 1 mm, vacuum pickup tools should be used to prevent localized plastic deformation of the pore walls. Store in a dry, temperature-controlled environment; while the material is inherently acid-alkali resistant per ISO 11845:1995, prolonged exposure to concentrated oxidizing acids may cause gradual surface passivation. Proper handling preserves the open-cell architecture critical for electrochemical and thermal performance.

Assessment

This porous nickel foam offers a 95% porosity 3D reticulated structure with high electrical conductivity and thermal stability up to 1100°C, making it suitable for battery electrodes and catalytic supports. However, its delicate structure requires careful handling and pre-conditioning in high-temperature oxidizing environments.

Positive

Ultra-lightweight high surface area: With 95–98% porosity and bulk density 0.1–0.8 g/cm³, the foam provides an exceptionally large specific surface area for active material loading and charge transfer in battery electrodes and catalyst supports.
High-temperature corrosion resistance: Retains mechanical stability and electrical conductivity up to 1100°C, and is acid and alkali resistant per ISO 11845:1995, enabling use in harsh electrochemical and thermal environments.

Trade-offs

Delicate structure handling: Thin sheets (<1 mm) require vacuum pickup tools to avoid localized plastic deformation of pore walls; the material is supplied with protective packaging to preserve the reticulated structure.
Pre-conditioning for high-temperature use: For oxidizing atmospheres above 500°C, pre-conditioning in a reducing environment (H₂/Ar) is recommended to remove surface oxides and restore full electrical conductivity.

Quality Standards & Performance Verification

Every advanced material, component, equipment, and instrument in our catalog is backed by rigorous testing. We maintain strict internal quality management frameworks and align with CE conformity metrics to deliver transparent, reproducible performance data via our public open-science repository.

To request raw batch performance data, submit formal vendor registration paperwork, or execute a fast-turnaround R&D manufacturing loop, contact us at inquiry@atomfair.com.

Shipping & Returns

Item is dispatched under the Atomfair Shipping & Delivery Framework (Free worldwide shipping on orders over $59 USD excl. heavy equipment). Return is governed by the Atomfair Return & Refund Policy (7-day technical return window).