One way to protect mild steel from corrosion is by coating it with nanostructured film. In this study Aluminium nanostructured coatings were successfully coated on the mild steel substrate by electron beam thermal evaporator technique. This study investigate the effect of annealing on the topography and morphology of Al nanostructured films via AFM and FESEM. The deposition current and time of Al-coated on mild steel is optimized at 60 A_5min, changed the morphology of coatings with more smooth compact coatings structure. The Al-nanostructured films were annealed at temperatures ranging from 300 °C-500 °C. The surface morphology was observed by field emission scanning microscopy (FESEM). Meanwhile, the roughness and total grain boundary were characterised by atomic force microscopy (AFM). FESEM images revealed that smaller Al-nanostructured were densely grown at optimum temperature of 300 °C, 400 °C and 500 °C.

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