Abstract: The integral hydroforming process to prepare CLAM T-shapes for fusion applications was evaluated by means of numerical simulation. The paper firstly investigated the effect of different paths on the protrusion height and distribution of thickness thinning rate of T-shapes. Then, it discussed that the friction coefficient between die and tube blank played an important role in manufacturing high quality T-shapes. Subsequently, the practical hydroforming was performed based on the simulation results with the aid of special lubrication coatings with friction coefficient 0.07. It is obviously indicated that the simulation results agree well with the experimental ones in geometry size and wall thickness distribution. The results indicate that the numerical simulation guides the practical hydroforming of CLAM tube effectively and determines the actual cold forming process parameters rapidly. The sound CLAM T-shapes with proper geometry size and thickness distribution can be obtained by the optimal hydroforming process.