The titanium alloy bulkhead frame is one kind of the important components in the aircraft structure. It could be fabricated by using the new method of Electron Beam Welding (EBW) for parts assembly. An introduction is taken on the disadvantages of mechanical joints and Submerged Arc Welding for titanium bulkhead frame parts assembly, the advantage of EBW is distinct compared to the other two methods above. The Building Block Approach was adopted in the research of series tests. Firstly, the heat treat procedure of TC4-DT after welding was based on the welding specimen tension results according to specific parameter comparison. Secondly, the data base was built by doing series of experiments of standard specimen in tension, also for fracture toughness and crack growth rate. Finally, the EBW of TC4-DT titanium alloy bulkhead frame was successfully applied on the specific aircraft after doing short beam experiments and component experiments. Good mechanical properties of the welding joints was verified, and the weight reduction was distinct compared to the mechanical joints.