The present study deals with nanocomposite thin film coating, analysis and application steps for the corroding surfaces. Silica nanoparticles were incorporated into epoxy polymers, 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.