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Nitrogen–oxygen sensors are pivotal for NOX emission detection, and they have been designed as key components in vehicles’ exhaust systems. However, severe thermal stress concentrations during thermal cycling in the sensors create knotty structural damage issues, which are inevitable during the frequent start–stop events of the vehicles. Herein, to illustrate the effect of thermal concentration on a sensor’s structure, we simulated the temperature and stress field of a sensor through finite element analysis. The failure modes of the sensor based on the multilayer structure model were analyzed. Our simulation indicated that the thermal deformation and stress of the sensors increased significantly when the heating temperature in the sensors increased from 200 to 800 °C. High stress regions were located at the joint between the layers and the right angle of the air chamber. These results are consistent with the sensor failure locations that were observed by SEM, and the sensor’s failures mainly manifested in the form of cracks and delamination. The results suggest that both the multilayer interfaces and the shape of the air chamber could be optimized to reduce the thermal stress concentrations of the sensors. It is beneficial to improve the reliability of the sensor under thermal cycling operation.

Thermal Stress Simulation and Structure Failure Analyses of Nitrogen–Oxygen Sensors under a Gradual Temperature Field