The use of aluminum as a current collector in electrochemical power sources is desired because of the light weight and low cost of the metal. Power sources, including the lithium ion battery and the proton exchange membrane fuel cell, would benefit from a corrosion-resistant aluminum current collector that allows electrons to flow between the electrode and the aluminum. The rapid corrosion of aluminum in these applications, however, keeps such power source devices from being fabricated. Electrically conductive coatings on aluminum are required to prevent the base metal from corroding while allowing electrons to flow between the power sources' electrodes and the aluminum base metal. Various corrosion failure mechanisms have been investigated to identify how a fuel cell may fail due to coated aluminum bipolar plates. Two approaches are also discussed for reducing the corrosion process.
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