This study presents a sol-gel-based strategy to synthesize amorphous SiO(2 )nanoparticles and incorporate them into PMMA to form corrosion-resistant composite coatings for Ti-6Al-4V substrates. The effects of synthesis parameters precursor concentration, catalyst concentration, reaction time, and temperature on particle size and dispersion were systematically investigated. Voronoi-based dispersion index (D-0.2) was used to quantify uniformity, showing that catalyst concentration played the most critical role in dispersion control. Well-dispersed SiO(2 )nanoparticles (D-0.2 > 50%) significantly improved electrochemical barrier performance, as confirmed by electrochemical impedance spectroscopy (EIS). The optimal composite, containing 5 wt% SiO2, exhibited impedance magnitudes in the range of 10(8)-10(9) Omegacm(2 )at low frequencies and stable phase angles (80-90 degrees), indicating dense coating morphology and strong dielectric behavior. In contrast, higher filler content (10 wt%) led to aggregation, structural defects, and diminished corrosion protection. The findings confirm that nanoparticle dispersion is a key factor in coating integrity and validate a practical design route for highperformance polymer-based anticorrosion coatings.
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