Synthesis, processing and characterization of calcia-stabilized zirconia solid electrolytes for oxygen sensing applications

Precursor powders of calcia-stabilized zirconia (CSZ) solid electrolytes have been synthesized by a sol–gel method. The phase evolution of the precursor powders after thermal treatments at different temperatures were analysized by X-ray diffraction technique. Disc-shaped sensor elements were fabricated via uniaxial pressing of the calcined powders and subsequently sintered at 1650 °C. Scanning electron microscopy (SEM) was used to analyze the microstructure of the sintered pellets. Platinum electrodes were applied to the sintered elements to produce potentiometric/electrochemical gas sensors. The electrical response of the gas sensors to oxygen and the complex impedance of the sensors in air were measured at various temperatures. Impedance analyses indicate that the sensor cell with 15 mol% CaO has much lower resistance (the sum of bulk and grain-boundary resistance) than the sensor cell with 22 mol% CaO. This is also reflected by the EMF responses of both sensor cells to various oxygen concentrations in the testing gas. The EMF deviation from the theoretical value of the CSZ sensor cell with 22 mol% CaO was larger than that of the CSZ sensor cell with 15 mol% CaO. The corrrelations between material compositions, microstructures of the sintered pellets and the electrical properties of the sensors are discussed.