Processing the denture base materials produced unequal deformation in different dimensions (anterior-posterior and cross-arch). Each material tested also responded differently to the processing stages.

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This paper aims at analyzing the deformation behavior of tailor welded blanks (TWBs), manufactured by laser beam welding (LBW) and gas tungsten arc welding (GTAW), through the deep drawing process. Dissimilar and similar steels with different thicknesses were used in the production of tailor welded blanks. The Nd: YAG laser welding method with nitrogen (N2) as the shielding gas was used to join TWBs. The effects of some significant process factors, namely welding speed, blank holder forces (BHF), material properties of base metals, dry/lubricated condition and laser spot size was experimentally investigated on the weld line movement and drawing depth. Results indicated that using LBW with optimum parameters for the production of dissimilar TWBs caused the control of failure in the weaker base metal. Results showed that the sound welds were produced in similar TWBs with a thickness ratio of 2 when using GTAW, but the weld quality was poor when using LBW. Moreover, it is observed that the critical stresses were taken place outside of the weld zone and rupture due to the high heat input of laser and metallurgical changes of the base metal that occur in the pre-softening zone. In addition, the weld line movement occurred as a result of plastic strain change of the weld joint that caused failure-prone zone creation as well as the adverse wrinkling.