Gas sensor

A gas sensor, comprising:

• a gas sensor element extending in an axis direction of the gas sensor and including a bottomed cylindrical element body and an outer electrode, the element body being exposed to a gas under measurement at a front end side thereof and opened at a rear end side thereof and having a radially outwardly protruding flange portion, the outer electrode being formed on an outer surface of a front end portion of the element body located front of the flange portion;
• a cylindrical metal shell radially outwardly surrounding the gas sensor element and having, on an inner surface thereof, a seat portion tapered and inclined toward the front end side so as to face a front end-facing surface of the flange portion;
• and
• an annular metal portion arranged between the front end-facing surface of the flange portion and the seat portion,
• wherein the gas sensor further comprises a porous thermal spray layer formed on a region from the front end portion of the element body via the front end-facing surface to at least a side surface of the flange portion so as to cover the outer electrode;
• and
• wherein, when viewed in cross section along the axis direction, a corner connecting a radially outer side surface of the metal portion and a front end-facing surface of the metal portion is formed so as to axially overlap in position with or radially outwardly protrude from an outer surface of a part of the thermal spray layer located on the side surface of the flange portion and is brought into contact with the seat portion, and a rear end-facing surface of the metal portion is brought into contact with an outer surface of a part of the thermal spray layer located on the front end-facing surface of the flange portion at a position radially inside the side surface of the flange portion.