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Nanoplasmonic hydrogen sensors are predicted to play a key role in safety systems of the emerging hydrogen economy. Pd nanoparticles are the active material of choice for sensor prototype development due to their ability to form a hydride at ambient conditions, which creates the optical contrast. Here, we introduce plasmonic hydrogen sensors made from a thermoplastic nanocomposite material, that is, a bulk material that can be molded with standard plastic processing techniques, such as extrusion and three-dimensional (3D) printing, while at the same time being functionalized at the nanoscale. Specifically, our plasmonic plastic is composed of hydrogensensitive and plasmonically active Pd nanocubes mixed with a poly(methyl methacrylate) matrix, and we optimize it by characterization from the atomic to the macroscopic level. We demonstrate meltprocessed deactivation-resistant plasmonic hydrogen sensors, which retain full functionality even after SO weeks. From a wider perspective, we advertise plasmonic plastic nanocomposite materials for application in a multitude of active plasmonic technologies since they provide efficient scalable processing and almost endless functional material design opportunities via tailored polymer- colloidal nanocrystal combinations.

Metal nanoparticles are currently used in a variety of applications, ranging from life sciences to nanoelectronic devices to gas sensors. In particular, the use of palladium nanoparticles is gaining increasing attention due to their ability to catalyze the rapid dissociation of hydrogen, which leads to an excellent response in hydrogen-sensing applications. However, current palladium-nanoparticle-based sensors are hindered by the presence of hysteresis upon hydride formation and decomposition, as this hysteresis limits sensor accuracy. Here, we present a robust colloidal synthesis for palladium-gold alloy nanoparticles and demonstrate their hysteresis-free response when used for hydrogen detection. The obtained colloidal particles, synthesized in an aqueous, room-temperature environment, can be tailored to a variety of applications through changing the size, ratio of metals, and surface stabilization. In particular, the variation of the viscosity of the mixture during synthesis resulted in a highly tunable size distribution and contributed to a significant improvement in size dispersity compared to the state-of-the-art methods.

Hydrogen gas is rapidly approaching a global breakthrough as a carbon-free energy vector. In such a hydrogen economy, safety sensors for hydrogen leak detection will be an indispensable element along the entire value chain, from the site of hydrogen production to the point of consumption, due to the high flammability of hydrogen-air mixtures. To stimulate and guide the development of such sensors, industrial and governmental stakeholders have defined sets of strict performance targets, which are yet to be entirely fulfilled. In this Perspective, we summarize recent efforts and discuss research strategies for the development of hydrogen sensors that aim at meeting the set performance goals. In the first part, we describe the state-of-the-art for fast and selective hydrogen sensors at the research level, and we identify nanostructured Pd transducer materials as the common denominator in the best performing solutions. As a consequence, in the second part, we introduce the fundamentals of the Pd-hydrogen interaction to lay the foundation for a detailed discussion of key strategies and Pd-based material design rules necessary for the development of next generation high-performance nanostructured Pd-based hydrogen sensors that are on par with even the most stringent and challenging performance targets.

Surfactants and stabilizers are always present on the surfaces of colloidal nanocrystals due to their critical function in promoting selective facet growth and since they are essential to prevent aggregate formation in solution. After synthesis, however, the presence of these molecules on the surface of a nanocrystal is problematic because they potentially significantly alter the nature of the interaction with the environment, which is critical for sensor or catalysis applications. Here, we quantitatively scrutinize this effect experimentally for the four most common stabilizers in Pd nanoparticle synthesis: cetyltrimethylammonium bromide (CTAB), tetraoctylammonium bromide (TOAB), cetyltrimethylammonium chloride (CTAC), and poly(vinylpyrrolidone) (PVP). We use the surface-catalyzed hydrogen sorption and hydride formation reaction in Pd as a model system, due to its high relevance for hydrogen sensors. Specifically, we map in detail the (de)hydrogenation kinetics of arrays of nanofabricated Pd nanodisks in the presence of the surfactants and benchmark it with an uncoated Pd reference. As the key results, we find that the cationic surfactants significantly decelerate the (de)hydrogenation surface reaction, with the amplitude of deceleration mediated by the interplay between the halide-ion–Pd surface interaction strength and surfactant surface density. In contrast, a polymeric PVP coating is found to significantly accelerate hydrogen sorption. For the Pd-based hydrogen sensor application, our findings thus provide important insights for the appropriate choice of a surfactant to minimize the negative impact on hydrogen sorption kinetics and thus hydrogen detection response/recovery times. In a wider perspective, our results dramatically show how nanoparticles can attain different properties depending on what types of surfactants and stabilizers are present on their surface and how critical the quantitative understanding of their impact is for a specific application.

Hydrogen sensors are a prerequisite for the implementation of a hydrogen economy due to the high flammability of hydrogen-air mixtures. They are to comply with the increasingly stringent requirements set by stakeholders, such as the automotive industry and manufacturers of hydrogen safety systems, where sensor deactivation is a severe but widely unaddressed problem. In response, we report intrinsically deactivation-resistant nanoplasmonic hydrogen sensors enabled by a rationally designed ternary PdAuCu alloy nanomaterial, which combines the identified best intrinsic attributes of the constituent binary Pd alloys. This way, we achieve extraordinary hydrogen sensing metrics in synthetic air and poisoning gas background, simulating real application conditions. Specifically, we find a detection limit in the low ppm range, hysteresis-free response over 5 orders of magnitude hydrogen pressure, subsecond response time at room temperature, long-term stability, and, as the key, excellent resistance to deactivating species like carbon monoxide, notably without application of any protective coatings. This constitutes an important step forward for optical hydrogen sensor technology, as it enables application under demanding conditions and provides a blueprint for further material and performance optimization by combining and concerting intrinsic material assets in multicomponent nanoparticles. In a wider context, our findings highlight the potential of rational materials design through alloying of multiple elements for gas sensor development, as well as the potential of engineered metal alloy nanoparticles in nanoplasmonics and catalysis.

Hydrogen (H2) sensors that can be produced en masse with cost-effective manufacturing tools are critical for enabling safety in the emerging hydrogen economy. The use of melt-processed nanocomposites in this context would allow the combination of the advantages of plasmonic hydrogen detection with polymer technology; an approach which is held back by the slow diffusion of H2 through the polymer matrix. Here, we show that the use of an amorphous fluorinated polymer, compounded with colloidal Pd nanoparticles prepared by highly scalable continuous flow synthesis, results in nanocomposites that display a high H2 diffusion coefficient in the order of 10-5 cm2 s-1. As a result, plasmonic optical hydrogen detection with melt-pressed fluorinated polymer nanocomposites is no longer limited by the diffusion of the H2 analyte to the Pd nanoparticle transducer elements, despite a thickness of up to 100 μm, thereby enabling response times as short as 2.5 s at 100 mbar (≡10 vol. %) H2. Evidently, plasmonic sensors with a fast response time can be fabricated with thick, melt-processed nanocomposites, which paves the way for a new generation of robust H2 sensors.

Hydride-forming metal nanoparticles sustaining localized surface plasmon resonance have emerged as prototypical material to study the fundamentals of hydrogen-induced phase transformations. They have also been proposed as signal transducers in next-generation hydrogen sensors. However, despite high current interest in hydrogen sorption by nanomaterials in general and such sensors in particular, the correlations between nanoparticle size, shape, and composition, the amount of hydrogen absorbed, and the obtained optical response have not been systematically experimentally studied. Focusing on hydrogenated Pd, PdAu- and PdCu-alloy nanoparticles, which are of particular interest in hysteresis-free plasmonic hydrogen sensing, we find that at practically important Au/Pd and Cu/Pd ratios the optical response to hydrogen concentration is linear and, more interestingly, can be described by a single universal linear trend if constructed as a function of the H/Pd ratio, independent of alloy composition. In addition to this correlation, we establish that the amplitude of optical signal change is defined solely by the spectral plasmon resonance position in the non-hydrogenated state for a specific nanoparticle composition. Thus, it can be maximized by red-shifting the LSPR into the NIR spectral range via tailoring the particle size and shape. These findings further establish plasmonic sensing as an effective tool for studying metal-hydrogen interactions in nanoparticles of complex chemical composition. They also represent universal design rules for metal-hydride-based plasmonic hydrogen sensors, and our theoretical analysis predicts that they are applicable not only to the H/Pd/Au or H/Pd/Cu system investigated here but also to other H/Pd/Metal combinations.

Three-layer core-shell-nanoparticle nanoarchitectures exhibit properties not achievable by single-element nanostructures alone and have great potential to enable rationally designed functionality. However, nanofabrication strategies for crafting core-shell-nanoparticle structure arrays on surfaces are widely lacking, despite the potential of basically unlimited material combinations. Here we present a nanofabrication approach that overcomes this limitation. Using it, we produce a library of nanoarchitectures composed of a metal core and an oxide/nitride shell that is decorated with few-nanometer-sized particles with widely different material combinations. This is enabled by resolving a long-standing challenge in this field, namely the ability to grow a shell layer around a nanofabricated core without prior removal of the lithographically patterned mask, and the possibility to subsequently grow smaller metal nanoparticles locally on the shell only in close proximity of the core. Focusing on the application of such nanoarchitectures in plasmonics, we show experimentally and by Finite-Difference Time-Domain (FDTD) simulations that these structures exhibit significant optical absorption enhancement in small metal nanoparticles grown on the few nanometer thin dielectric shell layer around a plasmonic core, and derive design rules to maximize the effect by the tailored combination of the core and shell materials. We predict that these structures will find application in plasmon-mediated catalysis and nanoplasmonic sensing and spectroscopy.

Hydrogen–air mixtures are highly flammable. Hydrogen sensors are therefore of paramount importance for timely leak detection during handling. However, existing solutions do not meet the stringent performance targets set by stakeholders, while deactivation due to poisoning, for example by carbon monoxide, is a widely unsolved problem. Here we present a plasmonic metal–polymer hybrid nanomaterial concept, where the polymer coating reduces the apparent activation energy for hydrogen transport into and out of the plasmonic nanoparticles, while deactivation resistance is provided via a tailored tandem polymer membrane. In concert with an optimized volume-to-surface ratio of the signal transducer uniquely offered by nanoparticles, this enables subsecond sensor response times. Simultaneously, hydrogen sorption hysteresis is suppressed, sensor limit of detection is enhanced, and sensor operation in demanding chemical environments is enabled, without signs of long-term deactivation. In a wider perspective, our work suggests strategies for next-generation optical gas sensors with functionalities optimized by hybrid material engineering. Sensing hydrogen by the change in plasmonic response upon metal hydride formation is safe, but trace gas poisoning and low sensitivity can occur. Here, a PdAu alloy/polymer sensor is poison resistant and can sense 3 ppm H2 with a response time of 1 s.