Process for making thin film porous ceramic-metal composites and composites obtained by this process

A composite comprising:

• a thin film porous ceramic layer coated on a substrate, the porous ceramic layer being in a suitable crystalline form such as zirconia in a cubic phase stabilised by a chemical moiety, wherein the ceramic layer is strongly adhered directly to the substrate, and
• a metal incorporated in or on the ceramic layer.

A catalytic element comprising:

• a thin film porous ceramic layer coated on a metal substrate, the porous ceramic layer being in a suitable crystalline form such as zirconia in the cubic phase, stabilised by a chemical moiety, wherein the ceramic layer is strongly adhered directly to the substrate, and
• a catalytic metal incorporated in or on the ceramic layer.

A thin film gas sensor comprising:

• a thin film porous ceramic layer coated on a substrate, the porous ceramic layer being in a suitable crystalline form such as zirconia in the cubic phase stabilised by a chemical moiety, wherein the ceramic layer is strongly adhered directly to the substrate, and
• a metal incorporated in or on the ceramic layer.

A thin film metal plated composite comprising:

• a thin film porous ceramic layer coated on a substrate, wherein the porous ceramic layer, such as zirconia, is adhered directly to the substrate by strong bonding, wherein the ceramic is in a suitable crystalline form such as the cubic phase stabilised by a chemical moiety and incorporating one or more metals or metal oxides therein or thereon, and
• a metal film plated upon the ceramic layer.