Gas sensor having an insulating layer

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Disclosed herein is a ceramic part, gas sensor, and method for making the gas sensor. The ceramic part comprises : an insulating layer affixed to a substrate wherein the insulating layer comprising Al2O3 particles; and a glass comprising about 45 to about 69 mole percent SiO2, 0 to about 9 mole percent B2O3, 0 to about 26 mole percent Al2O3, 0 and 25 mole percent SrO, and about 10 to about 26 mole percent RE2O3, where RE2O3 is selected from the group consisting of Y2O3, three valent rare earth oxides, and combinations comprising at least one of the foregoing. In one embodiment of a ceramic part, a gas sensor comprises : an electrolyte layer having disposed on opposite sides thereof a first electrode and a second electrode; and an insulating layer that is in intimate contact with the second electrode, wherein the insulating layer comprises alumina and frit. The method of making the gas sensor comprises : disposing a first electrode and a second electrode on opposite sides of an electrolyte layer; forming an insulating layer comprising alumina and frit; disposing the insulating layer adjacent to the second electrode to form a green sensor; and heating the green sensor to a temperature sufficient to sinter the electrolyte layer and the insulating layer.