This study evaluates the effects of an electroless Ni-Cu-P/nano-graphite composite coating on the surface characteristics of anodized 5083 aluminum alloy, including electrical resistivity, corrosion resistance of the alloy in a simulated solution of 0.5 M H2SO4 + 2 ppm NaF in polymer electrolyte membrane fuel cells (PEMFCs). The co-deposition and adhesion of the composite coatings on a 5083 substrate are enhanced by an anodizing process. The electroless Ni-Cu-P plating solution is prepared by adding different CuSO4 center dot 5H(2)O concentrations into the electroless Ni-P plating solution and adding nano-graphite (15-40 nm) particles to form the Ni-Cu-P/nano-graphite composite coatings. Experimental results indicate that the electroless Ni-Cu-P/nano-graphite composite coating enhances the hardness, conductivity, corrosion resistance of the 5083 substrate in the corrosive solution. The anodizing treatment enhances the electroless composite coatings by providing better uniformity, density, and adhesion compared to substrate without anodizing treatment. The electroless Ni-Cu-P/nano-graphite composite coating deposited on the optimal anodized 5083 substrate at a low CuSO4 center dot 5H(2)O concentration of 0.25 g I-1 with 20 g I-1 nano-graphite added have the best surface structure, highest hardness, electrical conductivity and corrosion resistance. Therefore, this novel electroless Ni-Cu-P/nano-graphite composite-coated 5083 aluminum alloy has potential applications in bipolar plates of PEM fuel cells. (C) 2012 Elsevier B.V. All rights reserved.