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.

Aviation products demand exceptionally high safety standards, where welding quality directly impacts structural integrity and flight safety. Welded joints must possess high strength and fatigue resistance. Since the welding process cannot be fully inspected and is classified as a special process, its manufacturing and production procedures require strict control, making the completeness of process specifications particularly crucial. Currently, the formulation of welding process specifications primarily relies on the production experience of process designers, with excessive focus on equipment processing parameters. This often leads to unstable product quality during production and fails to provide valuable references for aircraft structural designers. To enhance the performance, stability, and cost-effectiveness of Aviation welded products, this paper thoroughly considers the design requirements for welded products. It analyzes the full spectrum of elements within process specifications based on trade-off design. A structural model for welding process specifications is proposed, and a knowledge-driven methodology for standard verification and determining critical indicators is investigated. Using a laser welding production process as a case study, the structural model for Aviation product welding process specifications is validated.