ZnO nanostructured coatings have been prepared on Al2O3 substrates fitted with Au electrodes on one side and a Pt heater on the other, forming a solid-state gas sensor. The coatings were deposited by solution precursor plasma spraying (SPPS) using aqueous zinc acetate as the precursor solution. FE-SEM images show that the coatings are nanostructured with grain sizes of 50-100 nm. Surface morphology and grain size were found to be influenced by the flow rate of H2 in the plasma forming gas. The gas sensing function was characterized by measuring the electrical resistance of the coating in the presence of NO2 gas, showing good sensitivity down to the sub-ppm range.

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