Blending hydrogen into existing natural gas pipelines offers a cost-effective route for hydrogen transportation, yet hydrogen's distinct physicochemical properties and the geometric heterogeneity of industrial piping can alter explosion dynamics and increase the hazard potential. Here, explosion characteristics and pressure responses of methane/hydrogen/air premixed mixtures is investigated in a variable cross-section pipe over a range of equivalence ratio (Φ) and hydrogen volume fraction (). The results show that the membrane rupture time decreases monotonically with increasing , whereas the rupture pressure fails to show a strictly positive correlation with . After membrane rupture, the flame morphology exhibits irregular transitions; the tulip flame becomes increasingly pronounced with rising , and a clear, complete tulip flame is observed only when ≥ 50 %. Furthermore, the propagation process triggers unstable oscillations, with primary instability oscillations displaying regular periodic patterns at Φ = 0.8 and Φ = 1.2. The maximum amplitude of unstable oscillations occurs at the variable cross-section chamber, with the peak oscillation amplitude reaching 101.69 kPa at Φ = 1 and = 30 %. Chemical kinetic analysis based on GRI-Mech 3.0 reveals that the endothermic reaction is consistently dominated by R38, while at Φ = 1.2, the dominant heat release reaction shifts from R10 to R52 as the increases.
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