Epoxy-silica based hybrid nanocomposite coatings have been developed with different organicinorganic contents by sol–gel process. Various ratios of ceria and zirconia colloidal dispersions as inorganic nanoparticles are uniformly distributed in the hybrid sol. The hybrid sols are prepared by hydrolysis and condensation of 3-glycidoxypropyltrimethoxysilane (GPTMS) and tetraethylorthosilicate (TEOS) in acidic solution using bisphenol A (BPA) and 1-methyl-imidazol (MI). A thin layer of each sol is coated on a micro-glass slide and 1050 aluminum alloy as substrates. The effect of alkoxysilane precursors (i.e. TEOS and GPTMS) and inorganic to organic molar ratio are investigated. Nanoindentation and dynamic mechanical analysis (DMA) performed to characterize the mechanical properties of the coatings in nanorange scale. It is revealed that all hybrid nanocomposite coatings had appropriate flexibility and strong interfacial interaction with the aluminum alloy substrate. It is proposed that the ceria and zirconia nanoparticles can be bonded to the surrounding of siloxane ring which can be induced high restriction in polymeric chain mobility in dynamic mechanical analysis. Nanoindentation tests showed that by increasing the inorganic phase in the nanocomposite, both elastic modulus and hardness increase, especially they are very intense in the higher levels of inorganic content.
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