AbstractEpoxy polymer nanocomposites filled with magnetite (Fe₃O₄) clay (B), named (B-DPA-PANI@Fe₃O₄) have been prepared at different filler loading (0.1, 0.5, 1, 3, 5 wt. %). The surface modification of clay by polyaniline (PANI) is achieved in the presence of 4-diphenylamine diazonium salt (DPA). The effects of the nanofiller loading on Tensile, mechanical and dielectric properties were systematically studied. Improved properties was highlighted for all reinforced samples. The addition of only 3 wt. % of the filler enhanced the tensile strength of the composites by 256%, and the glass transition temperature Tg by 37%. The dielectric spectra over a broad frequency showed a robust interface between the hybrid (B-DPA-PANI@Fe₃O₄) fillers and epoxy matrix. The results showed most significant improvement in corrosion inhibition using electrochemical impedance spectroscopy (EIS) in 3.5 wt % NaCl, as well as a significant response in oil sensing test. High charge transfer resistance of 110 × 10⁶ Ω.cm² using 3-wt % of filler was noted compared to 0.35 × 10⁶ Ω.cm² for the pure epoxy. The results obtained herein will open new routes for the preparation of efficient anticorrosion sensor coatings.