We report the influence of 100 keV H + ion beam irradiation on the surface morphology, crystalline structure, and transport properties of as-deposited Al-doped ZnO (Al:ZnO) thin films. The films were deposited on silicon (Si) substrate by using DC sputtering technique. The ion irradiation was carried out at various fluences ranging from 1.0 × 10 12 to 3.0 × 10 14 ions/cm 2 . The virgin and ion-irradiated films were characterized by X-ray diffraction, Raman spectroscopy, atomic force microscopy, and Hall probe measurements. Using X-ray diffraction spectra, 5 points Williamson-Hall plots were drawn to deduce the crystallite site and strain in Al:ZnO films. The analysis of the measurements shows that the films are almost radiation resistant in the structural deformation under chosen irradiation conditions. With beam irradiation, the transport properties of the films are also preserved (do not vary orders of magnitude). However, the surface roughness and the crystallite size, which are crucial parameters of the ZnO film as a gas sensor, are at variation with the ion fluence. As ion fluence increases, the root-mean-square surface roughness oscillates and the surface undergoes for smoothening with irradiation at chosen highest fluence. The crystallite size decreases initially, increases for intermediate fluences, and drops almost to the value of the pristine film at highest fluence. In the paper, these interesting experimental results are discussed in correlations with ion-matter interactions especially energy losses by the ion beam in the material. KEYWORDS Al-doped ZnO, atomic force microscopy, ion beam irradiation, sputtering, thin film 1 | INTRODUCTION The ZnO is a direct wide band gap semiconductor. Due to being nontoxic, inexpensive, and abundant in nature, ZnO finds several potential applications in new technology such as solar cells, piezoelectric, gas sensors, and optoelectronic communication. 1,2 The ZnO has more than one stable crystal structure. It can exist in hexagonal wurtzite as well as in cubic zinc blende structure. This feature of ZnO allows us to synthesize a tetrapod-like morphology with multifunctionality. The synthesis of nano-dimensional tetrapod ZnO with various morphologies, their unique properties, and functional applications such as photocatalytic, UV photodetection, and gas sensing are reported elsewhere. 3-5 By tailoring the morphology, the properties of ZnO can be tuned for diverse applications. For instance, the quasi 1-dimensional ZnO nanowires exhibit piezo-resistivity. 6 The pure ZnO thin films show lack of stability due to thermal edging in air or corrosive environment, and native point defects such as O vacancies make it resistive. 7,8 Therefore, ZnO films are commonly doped with group II and group III metal ions such as indium (In), aluminium (Al), gallium (Ga), copper (Cu), and cadmium (Cd) to enhance its structural, optical, and electrical properties. 9 The indium (In) doping in ZnO improves both electrical and optical properties, but In is toxic and costly as well due to natural...