In order to overcome the high price, weight and volume of non-porous graphite bipolar plates, metallic bipolar plates are being investigated as a substitute material. However, metallic materials can corrode under proton exchange membrane fuel cell (PEMFC) working conditions, leading to a degradation in the performance of the membrane. Previous work had shown that a polypyrrole coating on SS316L can significantly increase the corrosion resistance of the base material. In this study, a Taguchi design of experiment method was used to optimize the process parameters for the polypyrrole coating so as to produce the maximum corrosion resistance. Potentiodynamic and potentiostatic tests were used to determine the corrosion resistance of the polypyrrole-coated SS316L. Scanning electron microscopy (SEM) with energy dispersive X-ray (EDX) was used to characterize the coating thickness and coating appearance. Inductively coupled plasma optical emission spectroscopy (ICP-OES) was used to determine the metal ion concentration in the solution after corrosion. The interfacial contact resistance of SS316L with carbon paper was measured both before and after coating with polypyrrole. (c) 2008 Elsevier B.V. All rights reserved.