<p>This study investigates the hydrogen‒oxygen crossover behavior induced by membrane perforation in alkaline electrolyzers, assessing explosion risks during operation. Perforation defects were simulated using an experimental platform with transparent end plates to analyze the effects of perforation diameter, position, and operating power on gas mixing. Results demonstrate that membrane perforation significantly increases HTO (Hydrogen to Oxygen), with severity dependent on perforation size and proximity to flow inlets/outlets. Maximum hydrogen-oxygen crossover occurs at high-flow-velocity zones due to flow field heterogeneity and gas accumulation. In addition, Lower operating power intensifies HTO, while higher load dilutes HTO through increased oxygen output. Based on the experimental data, a predictive regression model was developed, capable of forecasting HTO under different perforation conditions with high accuracy (R² = 0.9499). The novelty lies in quantifying the correlation between diaphragm perforation and risk in alkaline electrolyzer, and providing reference for early fault detection and preventive maintenance.</p>