We report enhanced hydrogen-gas-sensing performance of a Ni-doped ZnO sensor decorated with the optimum concentration of reduced graphene oxide (rGO). Ni-doped ZnO nanoplates were grown by radio frequency sputtering, rGO was synthesized by Hummer's method and decorated by the drop cast method of various concentration of rGO (0-1.5 wt %). The current-voltage characteristics of the rGO-loaded sensor are highly influenced by the loading concentration of rGO, where current conduction decreases and sensor resistance increases as the rGO concentration is increased up to 0.75 wt % because of the formation of various Schottky heterojunctions at rGO/ZnO interfaces. With the combined effect of more active site availability and formation of various p-n heterojunctions due to the optimum loading concentration of rGO (0.75 wt %), the sensor shows the maximum sensing response of ∼63.8% for 100 ppm hydrogen at moderate operating temperature (150 °C). The rGO-loaded sensors were able to detect a minimum of 1 ppm hydrogen concentration and showed high selectivity. However, a further increase in the rGO concentration (1.5 wt %) leads to the reduction of the relative response of hydrogen gas, ascribed to the formation of interconnections of rGO between electrodes. Therefore, it reduces the total resistance of the sensor and minimizes the effect of p-n heterojunction on sensor response.

We report highly hydrogen selective Pd contacted ZnO nanorods based sensor detecting low concentration even at low operating temperature of 50 °C. The sensor performance was investigated for various gases such as H2, CH4, H2S and CO2 at different operating temperatures from 50 °C to 175 °C for various gas concentrations ranging from 7 ppm to 10,000 ppm (1%). The sensor is highly efficient as it detects hydrogen even at low concentration of ~7 ppm and at operating temperature of 50 °C. The sensor’s minimum limit of detection and relative response at 175 °C were found 7 ppm with ~38.7% for H2, 110 ppm with ~6.08% for CH4, 500 ppm with ~10.06% for H2S and 1% with ~11.87% for CO2. Here, Pd exhibits dual characteristics as metal contact and excellent catalyst to hydrogen molecules. The activation energy was calculated for all the gases and found lowest ~3.658 kJ/mol for H2. Low activation energy accelerates desorption reactions and enhances the sensor’s performance.

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Uniformly distributed and defect-free vertically aligned ZnO nanorods (NRs) with high aspect ratio are deposited on Si by sputtering technique. X-ray diffraction along with transmission electron microscopy studies confirmed the single crystalline wurtzite structure of ZnO. Absence of wide band emission in photoluminescence spectra showed defect-free growth of ZnO NRs which was further conformed by diamagnetic behavior of the NRs. H2 sensing mechanism based on the change in physical dimension of channel is proposed to explain the fast response (∼21.6 s) and recovery times (∼27 s) of ZnO NRs/Si/ZnO NRs sensors. Proposed H2 sensor operates at low temperature (∼70 °C) unlike the existing high temperature (>150 °C) sensors.