Acetone Sensors Based on Al-Coated and Ni-Doped Copper Oxide Nanocrystalline Thin Films

Acetone detection is of significant importance in various industries, from cosmetics to pharmaceuticals, bioengineering, and paints. Sensor manufacturing involves the use of different semiconductor materials as well as different metals for doping and functionalization, allowing them to achieve advanced or unique properties in different sensor applications. In the healthcare field, these sensors play a crucial role in the non-invasive diagnosis of various diseases, offering a potential way to monitor metabolic conditions by analyzing respiration. This article presents the synthesis method, using chemical solutions and rapid thermal annealing technology, to obtain Al-functionalized and Ni-doped copper oxide (Al/CuO:Ni) nanostructured thin films for biosensors. The nanocrystalline thin films are subjected to a thorough characterization, with examination of the morphological properties by scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDX), and X-ray diffraction (XRD) analysis. The results reveal notable changes in the surface morphology and structure following different treatments, providing insight into the mechanism of function and selectivity of these nanostructures for gases and volatile compounds. The study highlights the high selectivity of developed Al/CuO:Ni nanostructures towards acetone vapors at different concentrations from 1 ppm to 1000 ppm. Gas sensitivity is evaluated over a range of operating temperatures, indicating optimum performance at 300 °C and 350 °C with the maximum sensor signal (<i>S</i>) response obtained being 45% and 50%, respectively, to 50 ppm gas concentration. This work shows the high potential of developed technology for obtaining Al/CuO:Ni nanostructured thin films as next-generation materials for improving the sensitivity and selectivity of acetone sensors for practical applications as breath detectors in biomedical diagnostics, in particular for diabetes monitoring. It also emphasizes the importance of these sensors in ensuring industrial safety by preventing adverse health and environmental effects of exposure to acetone.