Experimental and Computational Demonstration of a Highly Stable, in-situ Pt Decorated Sputtered ZnO Hydrogen Sensor for sub-ppm Level Detection

Abstract: In this work, we present a Pt decorated ZnO thin film-based gas sensor for hydrogen detection, fabricated using a sputtering technique and an in-situ Pt decoration approach. Specifically, we deposit a ZnO thin film on an interdigitated electrode substrate, with Pt nanoclusters added to the (002) polar plane by brief sputtering (1 to 6 s) to create an active sensing interface. Our sensor demonstrates optimal performance at an operating temperature of 498 K, with rapid response and recovery times (10 and 3 s), high selectivity, and long-term stability. We find the Pt decorated ZnO sensor, with a Pt deposition time of 2 s, to exhibit enhanced response (~52,987%) to 1% hydrogen concentration, indicating its suitability for industrial and environmental monitoring applications. Additionally, our device demonstrates reliable detection of low hydrogen concentrations (~100 ppb), with a response of ~38% and no response drift over one year of testing, underscoring the long-term stability of the sensor. To elucidate the role of Pt deposition and pristine ZnO in hydrogen sensing, we perform density functional theory calculations, analysing adsorption and reaction energetics involving H2, O2, O, OH, and H2O, and lattice oxygen atoms on the ZnO (002) surface with and without Pt decoration. Our computational data is in agreement with our experiments, identifying the oxygen-exposed (002) surface to be most active for hydrogen sensing in both pristine and Pt decorated ZnO. Further, our computations highlight the role of Pt in enhancing hydrogen sensitivity via i) activating an autoreduction pathway of adsorbed OH, ii) spontaneous dissociation of adsorbed molecular H2, and iii) keeping the lattice oxygen pathway of forming H2O active. Our systematic approach of designing sensors combining an experimental setup with theoretical insights, is key in developing and optimizing efficient hydrogen gas sensors.