The low-temperature pack chromization, a reforming pack cementation process, is employed to modify AISI 1045 steel for the application of bipolar plates in PEMFC. The process is conducted to yield a coating, containing major Cr-carbides and minor Cr-nitrides, on the substrate in view of enhancing the steel's corrosion resistance and lowering interfacial contact resistance between the bipolar plate and gas diffusion layer. Electrical discharge machining and rolling approach are used as the pretreatment to produce an activated surface on the steel before pack chromization process to reduce operating temperatures and increase deposition rates. The rolled-chromized steel shows the lowest corrosion current density, 3 x 10(-8) A cm(-2), and the smallest interfacial contact resistance, 5.9m Omega cm(2), at 140 N cm(-2) among all tested steels. This study clearly states the performance of 1045 carbon steel modified by activated and low-temperature pack chromization processes, which possess the potential to be bipolar plates in the application of PEMFC. (C) 2009 Elsevier B.V. All rights reserved.