Fullerene-decorated PdCo nano-resistor network hydrogen sensors with sub-second response and parts-per-billion detection at room temperature

Abstract Hydrogen detection with rapid response and ultra-low detection limits remains a critical challenge for safety and energy applications. Here, we report a fullerene-decorated PdCo nano-resistor network sensor that integrates nanostructuring, alloying, and surface-engineering approaches. The C 60 layer enhances sensor performance by increasing the surface-to-volume ratio, enabling fast hydrogen diffusion, relieving mechanical stress during cycling, and guiding nanostructure morphology. Our composite device (20 nm C 60 /3 nm Teflon AF/5 nm Pd 63 Co 37 /30 nm Teflon AF) achieves a response time of 0.40 ± 0.06 s across 1–100 mbar H 2 and detects 40 ppb H 2 with a signal-to-noise ratio of 10 at room temperature. A poly(methyl methacrylate) (PMMA) topcoat further improves cycling stability and selectivity under 90% relative humidity and interfering gases. This design provides a scalable approach and opens the door to future adaptation of porous carbon-based frameworks and polymeric interlayers to realize robust, high-performance hydrogen sensors for real-world applications.