Sol–gel synthesis of ZnO, ZrOx and InOx nanoparticles and their electrochemical decoration with nano-Au for semiconductor gas sensors

The on–board quantification of exhaust emission from the internal combustion engines is of global concern in order to monitor and control release of toxic gaseous pollutants such as the oxides of nitrogen (NOx). This scenario calls for highly performing, cost–effective and long lasting gas sensors. In this regard, semiconducting metal oxides present the foremost choice of active materials for real–time detection of exhaust gases due to their low cost, good electrical properties, high sensitivity and stability at temperatures as high as >500°C [1]. In this work, we report on the synthesis, analytical characterization, and surface modification of metal oxide nanoparticles (ZnO–, ZrOx, InOx- NPs) for their potential application as semiconductor gas sensors. ZnO is a promising material and one of the earliest oxides studied for gas adsorption [2]. However, owing to its high working temperature and limited selectivity, ZnO did not achieve commercial success. ZrOx and InOx nanomaterials are well known active components of NOx sensors, which have shown some performance limitations –either in selectivity or in response intensity and kinetics-. To overcome these limitations, in recent years semiconductor metal oxides (MO) are being frequently modified by selected inclusions of transition metal nanoparticles, bringing their own surface reactivity characteristics to the hybrid catalyst-MO system [3]. In the present study, MO–NPs are prepared via simple and economical sol–gel methods. The surface of MO–NPs is subsequently modified by electro–chemical decoration of nanoscale gold (nano–Au), performed under surfactant stabilization conditions. Since Au nanoparticles exhibit pronounced selectivity toward NOx gases [4], the nano–Au/MO–NPs hybrids are believed to enhance the sensing properties of MO–NPs such as the selectivity and long–term stability of the nanomaterial. Both the pristine MO–NPs and the composite nano–Au/MO–NPs are calcined at temperatures >500°C to induce stability at the usual operating temperature of gas-sensing experiments and the effect of calcination on nanostructure and morphology is systematically studied. The as–prepared and the calcined nanomaterials are characterized by transmission electron microscopy, scanning electron microscopy, X–ray photoelectron spectroscopy, and X–ray diffraction techniques. The results demonstrate that these nanomaterials are highly stable and even ultrafine gold nanophases retain their morphology and surface chemical speciation upon annealing. The experimental evidences support further application of these composite nano–Au/MO–NPs as active elements in semiconductor NOx gas sensors.