The effects of voltage and laser beam (spot) diameter on the penetration depth during laser beam welding in a representative nickel–chromium (Ni–Cr) dental alloy were the subject of this study. The cast alloy specimens were butted against each other and laser welded at their interface using various voltages (160–390 V) and spot diameters (0.2–1.8 mm) and a constant pulse duration of 10 ms. After welding, the laser beam penetration depths in the alloy were measured. The results were plotted and were statistically analyzed with a two-way ANOVA, employing voltage and spot diameter as the discriminating variables and using Holm–Sidak post hoc method (a = 0.05). The maximum penetration depth was 4.7 mm. The penetration depth increased as the spot diameter decreased at a fixed voltage and increased as the voltage increased at a fixed spot diameter. Varying the parameters of voltage and laser spot diameter significantly affected the depth of penetration of the dental cast Ni–Cr alloy. The penetration depth of laser-welded Ni–Cr dental alloys can be accurately adjusted based on the aforementioned results, leading to successfully joined/repaired dental restorations, saving manufacturing time, reducing final cost, and enhancing the longevity of dental prostheses
