The formation of organic-modified sol-gel coatings on 1050 aluminium alloy has been examined. The coatings were prepared by the combination of a completely hydrolysable precursor of tetra-n-propoxyzirconium (TPOZ), with a partly hydrolysable precursor of glycidoxypropyltrimethoxysilane (GPTMS). Influences of GPTMS/TPOZ ratio, withdrawal speed and curing temperature on the barrier-type corrosion protection of the alloy were examined. By control of process parameters and ratios of organic and inorganic moieties, crack-free sot-gel coatings with improved corrosion protection were produced on the alloy surface. Optimum protection was achieved by a coating formed with a GPTMS/TPOZ ratio of 2.7, a withdrawal speed of 180 mm/min and curing at 110 degrees C. The coating formed under the optimum conditions revealed good adhesion to the etched and desmutted alloy substrate. The pitting potential of the coated alloy increased significantly, indicative of an improved corrosion protection of the alloy. (C) 2010 Published by Elsevier Ltd.