I'm sure this has happened to most of us, but it just happened to me again, and I lost a lot of work. What? A face wiped out by a pose file setting all the morphs to zero. And I didn't notice until considerably too late. Really, a morph channel like "longface" that sets up a character, and one like "smile" that changes an expression, ought to be handled differently from one another and not get confused the way they are now. A bad bit of design that I hope will be fixed in Poser 5. Pose files are dangerous - there's no obvious way to tell what they will do.

A workaround some of the problems is to save a pose without saving the morphs (a choice on each save). You could put a pose on Dork, then resave it without the morph option which might allow that pose to be reused with less damage to faces.

After I have created a character face, I will save it as in the face file as default to unscrew problems after a pose has been applied.

It is difficult to separate morphs for expression from those for a character's face. I am not sure that Poser5 will fix this as the problem lies in the files. Some discrimination between expression morphs and face morphs would be useful.

Yes, if you are saving your own poses and remember each time not to save the morphs; no if you are using a downloaded pose. You have no way of telling what the pose does other than by trying it out. And in any case, it would be useful to be able to save the facial expression with a pose without changing the actual face. The other way to be safe is to spawn a morph target of the character's face in repose.