Ultra-fast and sensitive magneto-optical hydrogen sensors using a magnetic nano-cap array

Magnetism in curved nano-geometries has opened a new path to design novel characteristics and phenomena that could greatly impact the future fundamental and applied studies of materials. In this report, a hexagonally-packed array of magnetic nano-caps (or nano-patches, NP) exhibiting unique magnetic anisotropy and optimal nanostructure for fast hydrogen kinetics is explored as a sensing element for the spark-free magnetic-circular-dichroism (MCD) H2 sensor. The MCD H2 sensor outperforms the state-of-the-art optical sensors reported to date and satisfies the most challenging performance targets imposed by US Department of Energy. In particular, a Pd67Co33 NP sensor exhibits response time of t90 < 0.9 s, recovery time of t10 < 9.0 s over the 1–100 mbar H2 partial pressure range, and limit of detection (LOD) of ∼1 ppm. The LOD improves to < 700 ppb, when the signal-to-noise ratio is enhanced by stacking three NP arrays. Using a 30-nm TAF (Teflon AF 2400) polymer coating, the sorption kinetics of the Pd67Co33/TAF sensor are significantly accelerated, with t90 < 0.4 s and t10 < 2.8 s over the same pressure range. When the Pd67Co33/TAF sensor is further coated with a 100-nm poly(methyl methacrylate) (PMMA) layer, a rapid sorption time of t90 < 0.5 s, LOD < 1 ppm and excellent sensor accuracy (<2.5% full scale) are maintained, while the sensor obtains strong selectivity against interference gases and moisture, and a negligible aging effect. The MCD nano-cap sensor platform may have a great impact on the future deployment of H2 fuel, environmental monitoring H2 sensors, and fast proton-based magneto-ionic devices.