为解决氢致延迟断裂制约超高强马氏体钢在汽车工业中规模化安全应用的核心瓶颈，本工作以1500 MPa级冷轧超高强马氏体钢为研究对象，系统比较了冲切与线切割工艺对切边区域微观组织、显微硬度、残余应力及氢致开裂敏感性的影响。结果表明，冲切在边缘形成约200 μm的剪切影响区，引入显著加工硬化、峰值805 MPa的残余拉应力及微裂纹等预损伤，导致边部位错密度和氢陷阱密度显著升高，促进H的优先富集。慢应变速率拉伸实验表明，冲切试样在预充氢和原位浸泡充氢条件下的氢脆指数分别为50.6%和88.2%，显著高于线切割试样(7.2%和23.5%)。两类试样在原位浸泡充氢条件下的氢脆敏感性均高于预充氢条件，这归因于动态氢摄入与局部应力场的耦合效应，驱动H向晶界富集，诱发沿晶断裂。断裂机制分析结果表明，随着充氢方式的改变，冲切试样的断裂机制由预充氢条件下的氢增强局部塑性机制主导，转变为原位充氢条件下的吸附诱导位错发射与氢增强脱聚机制协同主导。剪切诱导的残余拉应力和塑性变形损伤是加剧氢脆的关键因素。

To meet the stringent demands of automotive lightweighting and crash safety, ultra-high strength martensitic steels are widely used in critical load-bearing body-in-white components. However, hydrogen embrittlement (HE) limits their large-scale application. In this study, a systematic investigation is conducted on the effects of shear cutting and electrical discharge machining (EDM) on the microstructure, microhardness, residual stress, and HE susceptibility of 1500-MPa-grade cold-rolled ultra-high strength martensitic steel. The results show that shear cutting generates a shear-affected zone (SAZ) of approximately 200 µm in width, characterized by pronounced work hardening, high residual tensile stresses (805 MPa), and pre-existing microcracks. These features substantially elevate dislocation and hydrogen trap density, thereby promoting hydrogen accumulation in the SAZ. Slow strain rate tensile tests reveal that the punched specimens exhibit HE indices of 50.6% and 88.2% under precharged and in situ hydrogen charging conditions, respectively. These values are notably higher than those of EDM specimens (7.2% and 23.5%). For both specimen types, HE susceptibility under in situ charging is markedly higher than under precharging, attributable to the coupled effects of dynamic hydrogen uptake and local stress fields, which drives hydrogen accumulation at grain boundaries and promotes intergranular fracture. Fractographic analysis reveals that the fracture mechanism in punched specimens transitions from hydrogen-enhanced localized plasticity dominated by precharging to a combination of adsorption-induced dislocation emission and hydrogen-enhanced decohesion under in situ charging. These findings demonstrate that shear-induced residual tensile stress and plastic deformation are the critical factors aggravating HE.