Novel structural modulation in ceramic sensors via redox processing in gas buffers

High selectivity, enhanced sensitivity, short response time, and long shelf-life are some of the key features sought in the solid-state ceramic-based chemical sensors. As the sensing mechanism and catalytic activity are predominantly surface-dominated, benign surface features in terms of small grain size, large surface area, high aspect ratio and, open and connected porosity, are required to realize a successful material. In order to incorporate these morphological features, a technique based on rigorous thermodynamic consideration of the metal/metal oxide coexistence is described. By modulating the oxygen partial pressure across the equilibrium M/MO proximity line, formation and growth of new oxide surface on an atomic/submolecular level under conditions of "oxygen deprivation," with exotic morphological features, has been achieved in potential sensor materials. This paper describes the methodology and discusses the results obtained in the case of potential semiconducting ceramic oxide-based carbon monoxide and hydrogen sensors with enhanced characteristics.