Further improvement in the performance of the polymer electrolyte membrane fuel cells as a power source for automotive applications may be achieved by the use of a new material in the manufacture of the bipolar plate. Several nickel alloys were applied on the aluminum substrate, the use of aluminum as a bipolar plate instead of graphite is to reduce the bipolar plate cost and weight and the ease of machining. The electroplated nickel alloys on aluminum substrate produced a new metallic bipolar plate for PEM fuel cell with a higher efficiency and longer lifetime than the graphite bipolar plate due to its higher electrical conductivity and its lower corrosion rate. Different pretreatment methods were tested; the optimum method for pretreatment consists of dipping the specimen in a 12.5% NaOH for 3 min followed by electroless zinc plating for 2 min, then the specimen is dipped quickly in the electroplating bath after rinsing with distilled water. The produced electroplate was tested with different measurement techniques, chosen based on the requirement for a PEM fuel cell bipolar plate, including X-ray diffraction, EDAX, SEM, corrosion resistance, thickness measurement, microhardness, and electrical conductivity. (c) 2007 Elsevier B.V. All rights reserved.