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Sunken weld is one of the common defects of tailor welded blanks (TWB), which seriously affects the strength of weld. The reasons for sunken weld are discussed based on theoretical analyses and experiments. The results show that sunken weld is affected by gaps and offsets. Positive offset (laser spot shifts to the thicker steel sheet) can reduce the harmful effects of gaps. Also, the limit of offset is discussed. The results have practical significance for improving welding quality.