Research on the Structural Model of Welding Process Specifications for Aviation Products Based on Trade-Off Design

The formulation of robust Welding Procedure Specifications (WPS) is paramount in aviation manufacturing, where quality directly impacts structural integrity and flight safety. Current practices, however, often rely on experiential knowledge and lack a systematic methodology for balancing performance, reliability, and economy, leading to unstable product quality and limited forward-design capability. This study addresses these gaps by proposing a novel, three-layer structural model for aviation WPS based on trade-off design principles. The model integrates a comprehensive correlation matrix linking product requirements to process elements, a modular architecture for enhanced reusability, and a knowledge-driven validation workflow. A key feature of the validation method is the use of a scientifically designed process test matrix and Statistical Process Control (SPC) to quantitatively determine process margins and capability indices (Cv, Cpk), moving beyond traditional pass/fail criteria. The application of this methodology is demonstrated and validated through a case study on electron beam welding. The results indicate that the proposed framework provides a systematic approach for developing stable, economical, and digitally ready welding process specifications, thereby significantly improving the forward-design capability in aviation welding.