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. Crown Copyright (C) 2012 Published by Elsevier Ltd. All rights reserved.