Aiming at overcoming the difficulties in integral forming of thin-walled tubes with complex shapes, a novel forming method by inner and outer pressure through viscous was proposed. In this method, by dividing large deformation of the part into inner and outer pressure forming deformations, the limit deformation of tube part can be increased by several times. Meanwhile, the principle of viscous inner and outer pressure forming was provided, and key problems during the forming process such as reduction of the wall-thickness and instability wrinkling were analyzed. Thereby, the complex curved surface super-alloy GH3044 thin-walled tube with varying diameter ratio of 1.35(the ratio between the maximum and minimum diameters of the part) can be integrally formed by this method. The experimental surface of the formed part is superior in quality and the wall-thickness distribution is uniform. The results show that the viscous inner and outer pressure forming can provide a new approach for integral forming of thin-walled tubes with complex shapes.
