Lightweight metal bipolar plates and methods for making the same

A bipolar plate comprising:

• a metal substrate selected from Mg, Al, Mg alloys and Al alloys;
• and
• a metal layer selected from Co, Pt, Au, Ir, Pd, Ru and mixtures thereof deposited on the substrate, wherein the metal layer is deposited on the substrate from a non-aqueous solution.

A process for making lightweight bipolar plate comprising:

• deoxidizing a metal substrate selected from Mg, Al, Mg alloys and Al alloys;
• and
• depositing a first metal layer on the metal substrate using a non-aqueous solution selected from a molten salt having a cation containing at least one tetravalent nitrogen atom and a halogenated aluminum species.

A process for making a lightweight bipolar plate comprising:

• deoxidizing a metal substrate selected from Mg, Al, Mg alloys and Al alloys;
• and
• depositing a first metal layer on the metal substrate using a non-aqueous molten salt solution.

A lightweight bipolar plate, comprising:

• a light metal selected from aluminum, magnesium, aluminum alloys and magnesium alloys;
• wherein the surface of the light metal is coated with at least one layer of a metal, and wherein the at least one layer of a metal comprises an electroplated metal-polytetraluoroethylene composite coating.