I don't recall Xi'an being brought up at the time. Yongle moved the capital because when he staged the coup against Jianwen, it did it by taking command of all the Great Wall troops, and forming close relationships with many of the Mongol generals who joined the Ming when the Yuan collapsed. If he didn't move the capital to Beijing then someone else will probably pull the same trick as him again. Xi'an only makes sense in the context of the Silk Road and having a fertile agricultural valley with easily defended mountain passes, but from the Tang dynasty the main agricultural area had shifted to Jiangnan and the overland Silk Road was less and less important due to maritime technology. Also, during the Jin & Yuan dynasties the Grand Canal from Henan to Hebei had fallen into disrepair and replaced with the Jiangsu to Hebei Canal, so the capital couldn't even be in Henan which had become too isolated from the grain supply lines to keep an eye on the most crucial lifeline of the dynasty. Just to give you a picture of how important the Grand Canal is: when Zheng Chenggong counterattacked Nanjing in 1656, the Manchus almost decided to retreat to Manchuria because Beijing was going to starve to death without the Jiangnan grain supply.
I think the substantial mention of architectural work in Xi'an indicates that the capital was to move to Xi'an under the crown prince (who I think died after returning from a tour of Xi'an).
Yeah, the move to Beijing was to return to his center of power.
If the capital had been moved to Xi'an, many of the later foreign attacks on the capital would not have been nearly as easy as they were with the capital in Beijing. That's really my reasoning for capital movement to Xi'an being preferable to movement to Beijing. At least Xi'an could feed itself.
It was Zhu Yuanzhang's intention in his last days to move to Xi'an. Xi'an was the last place among many others that was considered by Zhu Yuanzhang. The consideration was so serious that he let the crown prince to personally travel to Xi'an who recommended Xi'an as the capital before his death.
《明史-列传第三》载:“二十四年八月,敕太子巡抚陕西……御史胡子祺上书曰:‘……夫据百二河山之险,可以耸诸侯之望,举天下莫关中若也。’帝称善。至是,谕太子曰:‘天下山川惟秦地号为险固,汝往以省观风俗,慰劳秦父老子弟。’……比还,献陕西地图,遂病。病中上言经略建都事。”
The crown prince died before Zhu Yuanzhang who was too old to make the move. The bold texts about "let the heaven to determine the fate" referred to his earlier opinion of Nanjing based dynasties having bad fates.
“今朕年老,精力已倦。又天下新定,不欲劳民。且废兴有数,只得听天!”(《天下郡国利病书·江宁庐州安庆备录·南京》)。
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