Alumina-zirconia (AZ) nanoparticles were synthesized via a pilot-scale hot-air spray pyrolysis method.The structural, morphol., and chem. characteristics of the synthesized AZ nanoparticles were systematically characterized.The nanoparticles reveal a high-crystalline t-ZrO2-stabilized amorphous alumina matrix with a crystalline size of 9.7 nm and a particle size of 20 nm, exhibiting a highly spherical shape morphol. and a surface area of 36.28 m2/g.Hybrid nanocomposite coatings were fabricated on mild steel (MS) specimens by incorporating varying concentrations of AZ nanofillers (0.05, 0.10, and 0.15 wt%) of filler into epoxy resin (EH) with subsequent functionalization of oleic acid.Results showed that higher concentrations of alumina-stabilized t-ZrO2 nanoparticles led to a significant reduction in surface porosity of nanocomposite coating, from 1.106 to 0.319 μm.Meanwhile, it exhibited a hardness of 292 MPa, Young′s modulus of 2.34 MPa, and surface roughness of 1.237 nm with a maximum contact angle of 82.92 ± 5.60, demonstrating enhanced mech. strength and a more hydrophobic nature.Electrochem. analyses, such as the Nyquist Plot and Tafel polarization plot, revealed that nanocomposite coatings significantly improved corrosion resistance in a saline medium of 3.5 wt% NaCl and natural seawater environments, achieving efficiencies of 95.88 % and 82.36 %, resp.These findings highlight the potential of AZ-reinforced epoxy nanocomposite coatings as advanced anticorrosion applications in real-time seawater conditions.