Aluminum has many advantages for commercial bipolar plate of PEM fuel cell such as light weight, low
cost and easy manufacturing. However, it has a low corrosion resistance under a PEM fuel cell operation
condition that is a special issue of all metal bipolar plates. In this study, polypropylene composite coated
with aluminum bipolar plates were fabricated to improve the corrosion resistance. However, contact
resistance of polymer composite coated aluminum bipolar plate is highly increased due to high contact
resistance between aluminum substrate and composite layer. Two different types of inter layers were
added to improve the contact resistance. Carbon paper attached and carbon black added samples were
fabricated between aluminum substrate and composite. Polyamide-imide/carbon black composite
adhesive was used for carbon paper attached on the aluminum plate. The contact resistance of carbon
paper attached sample was lower than that of carbon black added sample. And, corrosion resistance was
tested by potentiodynamic and potentiostatic methods. The composite coated aluminum attached to
carbon paper exhibited properties suitable for PEM fuel cells