The transition towards hydrogen as a clean energy carrier necessitates the development of robust pipeline systems that can withstand the unique challenges posed by hydrogen transport. Existing pipelines, often constructed from traditional materials, face risks such as hydrogen-induced embrittlement and degradation over time. Concurrently, novel hybrid pipelines made from woven carbon fiber reinforced plastics (CFP) offer significant advantages, including high strength-to-weight ratios and excellent corrosion resistance. However, their interaction with hydrogen presents new challenges that must be addressed.

This study explores innovative hydrogen-resistant coatings applied to both existing steel pipelines and novel hybrid structures utilizing woven carbon fiber through the High-Speed Directed Energy Deposition (DED) process. A central focus of this research is the adaptation of the process and its peripherals to enable effective internal coating of these hybrid pipeline systems in field applications.

By integrating additive manufacturing techniques with protective coatings developed via the HS DED process, this work aims to provide insights into strategies for enhancing the durability and integrity of hybrid pipeline infrastructures. Ensuring reliable and long-lasting performance in hydrogen transportation will support the broader adoption of hydrogen as a sustainable energy source.