The present study deals with nanocomposite thin film coating, analysis and application steps for the corroding surfaces. Silica nanoparticles were incorporated into epoxy^olymers, and then the obtained polymeric nanocomposites were sprayed on the Al coupons by a nozzle sprayer at different thicknesses. A urethane top layer was also coated on some of initially-coated surfaces. Several electrochemical impedance spectroscopy (EIS) tests were conducted on the prepared samples using 0.5 M NaCl solution. The test results showed that the Al coupons coated by nanocomposites and urethane top coating gave the excellent corrosion resistance against the corrosion attack. As a result, it is assumed that the nanostructured coating system will allow military, private companies and government agencies to effectively protect the materials surfaces against corrosion.
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