Metal Powder Making Machine

In the field of modern advanced manufacturing, metal powder manufacturing equipment occupies a pivotal position, serving as the crucial starting point of the entire industrial production chain. With the rapid advancement of technology, the demand for high-performance materials across various industries continues to grow. As a fundamental and essential raw material, the quality and performance of metal powders directly affect the quality and properties of the final products.

Powder metallurgy (PM) is a technology that produces materials and components using metal powders or mixtures of metal and non-metal powders through forming, sintering, and other processes. Metal powder serves as the indispensable foundation of this process. Through powder metallurgy, materials with special properties—such as high strength, hardness, heat resistance, and corrosion resistance—can be produced. These materials are widely used in aerospace, automotive manufacturing, and mechanical engineering.

For example, in the aerospace industry, powder-metallurgy-based nickel superalloys are used to manufacture turbine disks and blades, significantly enhancing engine performance and reliability. In the automotive sector, PM components are used in powertrain systems, such as valve seats and piston rings, improving engine durability and efficiency.

Additive manufacturing (AM)—commonly known as 3D printing—also heavily depends on metal powders. By layer-by-layer deposition of fine metal powders, AM enables the production of complex geometries that are difficult or impossible to achieve through traditional manufacturing methods. This process accelerates the transformation from design to final product, bringing new opportunities for innovation and efficiency in manufacturing. In the medical field, AM allows the production of customized metal implants tailored to individual patient needs. In aerospace, it enables the fabrication of lightweight, high-performance components that improve overall aircraft performance and fuel efficiency.

Therefore, metal powder manufacturing equipment, as the core technology for producing metal powders, directly determines the quality and characteristics of the powders, and in turn, profoundly influences the development of powder metallurgy, additive manufacturing, and other advanced manufacturing technologies. It has become a key driver of innovation and progress across industries.

For sectors such as powder metallurgy and additive manufacturing, the performance of metal powder manufacturing equipment directly affects both product quality and production cost. Understanding the core functions of this equipment helps enterprises select suitable systems and processes, reduce costs, and enhance competitiveness. Furthermore, it plays a crucial role in promoting technological innovation, industrial upgrading, and sustainable development.

In industries with exceptionally high material performance requirements—such as aerospace, medical, and automotive manufacturing—high-quality metal powders are the foundation for producing high-performance components. The insights provided in this guide offer strong technical support to these sectors, helping them manufacture safer, more reliable, and higher-performing products. Ultimately, this contributes to meeting the market’s growing demand for advanced manufacturing and supports the high-quality development of modern industries.

2.1, Definition and Classification

Metal powder manufacturing equipment, commonly known as an atomizer, is a key device capable of transforming solid metal into fine metal powder. Its operating principle is based on specific physical processes—melting, atomization, and solidification—through which solid metal is converted into powder form. This transformation plays a crucial role in modern manufacturing, providing the essential raw material for subsequent processes such as powder metallurgy and additive manufacturing.

Common types of atomizers include Inert Gas Atomization (IGA), Water Atomization (WA), Plasma Atomization (PA), and Ultrasonic Atomization (UA) systems. These atomizers differ in structure, working principle, and application areas.

• IGA equipment uses high-pressure inert gas to disintegrate a molten metal stream, achieving atomization.
• WA equipment employs high-pressure water jets to break up the molten metal stream, which then solidifies into powder upon cooling in a water bath.
• PA equipment uses a plasma torch or induction coil to provide high thermal energy, enabling atomization or spheroidization of irregular powders.
• UA equipment relies on ultrasonic vibration to fragment molten metal into uniform droplets, which then solidify into fine metal powders.

The classification of atomizers mainly depends on their atomization medium and energy source. These two factors determine the atomizer’s performance characteristics and applicable materials.

• IGA systems, which use inert gas as the atomization medium, are ideal for producing high-purity metal powders, such as nickel-based superalloys.
• WA systems, using water as the atomization medium, offer low cost and high productivity, making them suitable for traditional powder metallurgy components and metal injection molding (MIM) applications.
• PA systems, powered by plasma or induction heat, can produce powders with excellent sphericity, narrow particle size distribution, and low oxide content, and are often used for highly reactive alloys such as Ti-6Al-4V.
• UA systems, which use ultrasonic vibration as the energy source, are typically used in research environments, small-batch or customized production, and for precious metal atomization.

2.2, Core Process Steps

The core process of metal powder manufacturing equipment mainly consists of three closely linked stages: melting, atomization (disintegration), and solidification. Each of these steps plays a critical role in determining the final quality and performance of the metal powder.

Melting is the first step in metal powder production, during which the raw material is heated until it reaches a molten state. To ensure strict control over the metal’s purity, the melting process is typically carried out in a vacuum environment (such as Vacuum Induction Melting, VIM) or under an inert gas atmosphere. In a vacuum environment, reactions between molten metal and gases such as oxygen or nitrogen in the air are effectively prevented, minimizing impurity introduction. Under an inert gas atmosphere, the inert gas isolates the metal from reactive external gases, maintaining a clean melting environment. For example, when melting easily oxidized metals such as titanium or aluminum, using vacuum or inert gas protection significantly reduces oxidation and improves metal purity.

Controlling the chemical composition and superheat of the metal melt is essential for ensuring the desired quality and performance of the final product. The chemical composition directly determines the physical and chemical properties of the metal. Therefore, during melting, it is crucial to precisely regulate the content of each element according to application requirements.
Superheat refers to the temperature of the molten metal above its melting point. An appropriate superheat ensures sufficient fluidity of the molten metal, which is beneficial for the subsequent atomization process. Insufficient superheat may result in poor fluidity and uneven atomization, while excessive superheat can lead to the volatilization or burning of certain elements, negatively affecting composition and properties.

Once the metal is fully melted, it enters the atomization stage. Atomization—also known as disintegration—is the process of directing the molten metal stream into a specially designed atomizing nozzle system, where high-energy forces such as high-pressure gas, water jets, plasma, or ultrasonic vibrations break the stream into fine droplets.

Different atomization methods operate based on distinct principles:

• Gas atomization typically uses inert gases such as nitrogen, argon, or helium. For instance, during the atomization of easily oxidized metals, nitrogen can form a protective film around molten droplets, preventing oxidation. The high-pressure gas exits through nozzles at high velocity, impacting the molten stream and breaking it into tiny droplets under strong shear forces.

• Water atomization employs high-pressure water jets to impact the molten metal stream. The interaction between water and metal breaks the stream into droplets, which quickly cool and solidify in a water bath to form metal powder.

The purity of the atomizing medium significantly influences powder quality. If the medium contains oxygen or moisture, these impurities may react with the molten metal during atomization, leading to oxidation. Oxidized metal droplets form thick oxide films, increasing viscosity and hindering the formation of spherical particles, which in turn reduces powder gloss and performance. In gas atomization, using low-purity inert gas containing traces of oxygen can result in oxide layers on the powder surface, reducing powder purity and performance, and ultimately affecting the quality of downstream products.

After atomization, the fine droplets enter the solidification stage. In this stage, droplets rapidly cool and harden in environments such as an atomization tower or water bath, forming spherical or near-spherical particles. In an atomization tower, droplets fall through a cooling gas stream, rapidly losing heat through thermal exchange; in a water bath, direct contact with water provides fast cooling due to its high heat capacity, completing the solidification process.

The solidification rate has a decisive impact on powder quality. Rapid solidification helps retain a fine microstructure and prevents the formation of undesirable phases within powder particles. When metal droplets solidify quickly, atoms lack sufficient time to diffuse, preserving certain structural and compositional characteristics from the liquid phase, resulting in fine grains and uniform microstructures. Conversely, if cooling is too slow, atomic diffusion can lead to grain growth and segregation, undermining metallurgical integrity. In gas atomization, insufficient cooling rates may produce coarse grains within particles, reducing powder strength and toughness and ultimately degrading performance in practical applications.

3.1, Inert Gas Atomization (IGA)

The core mechanism of Inert Gas Atomization (IGA) lies in utilizing the strong impact force of high-pressure inert gases—typically argon, nitrogen, or helium—to disintegrate a molten metal stream into fine droplets. In industrial applications, the Vacuum Induction Melting–Inert Gas Atomization (VIM–IGA) system represents a highly integrated setup that combines a vacuum induction melting unit with an inert gas atomization unit, forming a complete system from metal melting to powder production.

In the VIM–IGA system, the vacuum induction melting unit is responsible for the crucial melting process. Through induction heating, the metal raw materials are melted under vacuum conditions. This vacuum environment effectively prevents the molten metal from reacting with atmospheric gases such as oxygen and nitrogen, ensuring a high-purity melt. For easily oxidized metals such as titanium and nickel, vacuum melting significantly reduces oxygen content and enhances overall purity and quality.

Once the metal has been melted into a homogeneous liquid, it is transferred to the inert gas atomization unit. Here, the molten metal stream is directed through a specially designed guide channel to the atomizing nozzle. High-pressure inert gas is ejected at high velocity from the nozzle and interacts with the molten stream. The intense gas impact instantly fragments the molten metal into countless fine droplets. As these droplets fall freely through the atomization tower, they exchange heat with the surrounding inert gas, rapidly cooling and solidifying into metal powder. This integrated system design not only improves production efficiency but also ensures high powder quality and consistency.

In the production of high-performance powders, achieving high purity is of paramount importance. For materials such as nickel-based superalloys and iron-, cobalt-, or chromium-based specialty alloys, the VIM–IGA process has become an industry-leading technology due to its distinct advantages. The vacuum induction melting step effectively handles alloys that easily react with air. Under vacuum conditions, impurities such as oxygen and nitrogen can be thoroughly removed from the molten metal, resulting in extremely low gas content. This plays a vital role in improving powder purity and performance. High-purity powders can better maintain their original chemical composition and physical properties during subsequent processing, ensuring high quality and reliability in final products.

In the aerospace industry, high-purity metal powders produced by IGA are widely used in the manufacturing of critical components. Turbine blades and disks in aircraft engines operate under extreme conditions of high temperature, pressure, and rotational speed, demanding exceptional material properties. The high purity and superior characteristics of IGA powders meet these stringent requirements, ensuring efficient and reliable engine operation. In the medical device industry, IGA powders also play an important role. Metal powders used for implants must exhibit extremely high purity and biocompatibility to avoid adverse reactions within the human body. Powders produced via the IGA process fulfill these requirements, providing reliable raw materials for high-end medical manufacturing.

Powders produced by the IGA process possess several notable characteristics. They typically exhibit high purity, thanks to vacuum melting and inert gas protection, which effectively minimize impurity introduction. Their low oxygen content ensures stable performance during processing and use, reducing the risk of oxidation or degradation. Moreover, the powders have high bulk density, allowing for better mold filling and resulting in denser, stronger products during forming.

The morphology of IGA powders is generally spherical, which grants excellent flowability. In processes such as additive manufacturing (AM) and powder metallurgy (PM), good flowability ensures uniform powder spreading and deposition, thereby enhancing productivity and product consistency. However, the IGA method also has certain limitations. The resulting particle size distribution is relatively broad, with typically only about 40% of the powder falling within the optimal size range required for Laser Powder Bed Fusion (LPBF) and similar AM processes. This leads to significant material loss and increased production costs.

Additionally, due to gas turbulence and variations in particle flight speed, small particles may adhere to larger ones during atomization, forming “satellite particles.” The presence of these satellites can severely impair powder flowability, causing uneven powder spreading and molding, which negatively affects product quality and performance. To overcome these issues, continuous optimization in equipment design and process control is required to further improve powder quality and production efficiency.

3.2, Water Atomization (WA)

The working principle of Water Atomization (WA) equipment is based on the powerful fragmentation capability of high-pressure water jets. In the WA process, metal raw materials are first heated to a molten state and then guided into the atomization zone through a specially designed flow channel. At this point, high-pressure water is ejected at high velocity from specially designed nozzles, forming dense water jets. These jets strike the molten metal stream at extremely high speeds, and under the strong impact force, the molten metal is rapidly broken up into fine droplets.

During interaction with the water jets, these droplets continuously absorb water and rapidly cool. They are then further cooled and solidified in a water bath, ultimately forming metal powder. One of the key advantages of water atomization equipment is its low cost, mainly because water is an abundant and inexpensive atomizing medium. Compared with other atomization methods, WA offers significant cost advantages in both raw materials and operating expenses, making it suitable for large-scale production.

WA powders also exhibit excellent “green strength,” meaning that before sintering, the pressed powder compacts can maintain good structural integrity. This feature makes WA powders particularly advantageous in traditional powder metallurgy (PM) processes, where high compact strength is required during part forming.

The morphology of WA powders is typically irregular and rough, with particle sizes generally ranging from 50 to 1000 μm. Although this irregular shape can negatively affect powder flowability, it also provides certain unique benefits in specific applications.

In conventional powder metallurgy part manufacturing, the irregular particle shape of WA powders promotes mechanical interlocking and densification between particles. During the compaction process, these irregular particles interlock with one another, forming a dense structure that enhances the strength and density of the green compact.

In the field of Metal Injection Molding (MIM), WA powders are also widely used. The MIM process requires powders with good formability, and the irregular morphology and high green strength of WA powders enable them to better fill mold cavities during injection molding. This allows for the production of complex-shaped components while maintaining structural stability during the subsequent debinding and sintering stages.

Water pressure is one of the key factors influencing the particle size of WA powders. In the atomization process, the water pressure directly determines the jet’s impact force and fragmentation efficiency. Generally, higher water pressure produces finer powders. As water pressure increases, the velocity and kinetic energy of the jets also increase, resulting in stronger impact on the molten metal stream and finer droplet formation, which ultimately produces smaller powder particles.

In practical production, to produce fine powders for MIM applications, higher water pressures are typically required—generally in the range of 50 to 150 MPa. By precisely controlling water pressure, manufacturers can effectively regulate powder particle size to meet the requirements of different applications. For example, to produce powders with particle sizes between 100–200 μm, the water pressure is usually maintained at 50–80 MPa; for finer powders in the 50–100 μm range, the water pressure is increased to 80–150 MPa. This method of adjusting particle size through pressure control gives the WA process strong flexibility and adaptability across various industrial applications.

3.3, Plasma Atomization Technology (PA/PREP)

Plasma Atomization (PA) or the Plasma Rotating Electrode Process (PREP) utilizes the extremely high heat generated by plasma torches or induction coils to achieve metal atomization or the spheroidization of irregular powders.

In the PA process, a plasma torch generates a high-temperature plasma that rapidly heats the metal to extremely high temperatures, causing it to melt and atomize almost instantaneously. Plasma, characterized by its high energy density and temperature, provides sufficient energy to complete the melting and atomization process within a very short time frame.

The PREP process, on the other hand, employs an induction coil to generate a high-frequency magnetic field. The rotating metal electrode inside the magnetic field produces eddy currents, which heat and melt the metal. Under the effect of centrifugal force, the molten metal is ejected from the edge of the rotating electrode and atomized into fine droplets. These droplets rapidly cool and solidify during flight, forming metal powder.

The PA technology offers remarkable advantages in powder morphology and purity control. It produces highly spherical powders with sphericity levels typically ≥0.95, giving the powders excellent flowability and packing performance. Furthermore, PA can achieve an extremely narrow particle size distribution (e.g., 15–45 μm) and very low levels of oxides or contaminants. These properties make PA powders indispensable for applications that demand exceptional powder quality, such as Laser Powder Bed Fusion (LPBF) for processing high-reactivity alloys like Ti-6Al-4V, ensuring superior product quality and performance.

The PA process primarily uses wire feedstock due to its stable shape and dimensions, which help maintain a consistent feed rate during atomization. Wire also has a smooth surface and low impurity content, reducing contamination risk and ensuring high powder purity. The uniform diameter and straightness of the wire ensure stable and reliable feeding, avoiding atomization inconsistencies caused by irregular feed rates.

However, the high precision and purity of the PA process come with significant cost factors. It consumes a large amount of electrical energy to generate the high-temperature plasma necessary for melting and atomizing metals. The generation of plasma requires specialized equipment and power supplies, which are expensive to purchase and maintain. Additionally, PA uses inert gases such as argon or helium as shielding and atomizing media, further increasing operating costs. The use of high-purity wire feedstock, which is itself expensive, adds to the overall production cost. Consequently, when applying the PA process, manufacturers must carefully balance product quality requirements and cost-effectiveness to determine its suitability.

PA technology is particularly suited for high-reactivity alloys such as Ti-6Al-4V, which easily react with oxygen, nitrogen, or other gases in conventional atomization processes—leading to oxidation and contamination that degrade material performance. The PA process, conducted under high-temperature and inert-gas-protected conditions, effectively prevents such reactions, ensuring powders of high purity and superior performance.

In LPBF applications involving reactive alloys, the PA-produced powders—with their ultra-spherical shape, narrow particle size distribution, and low oxide content—enable uniform melting and solidification during laser scanning. This ensures the production of high-quality, dense components. In the aerospace industry, Ti-6Al-4V parts are widely used in critical applications such as aircraft structural components and engine parts, where high strength, low density, and excellent corrosion resistance are essential. PA-processed powders meet these stringent standards, providing reliable material support for manufacturing high-performance aerospace components.

3.4, Ultrasonic Atomization (UA)

The Ultrasonic Atomization (UA) process operates based on the cavitation and surface instability effects induced by ultrasonic vibration. In the UA process, metal feedstock is first heated to its molten state, and the molten metal is then delivered onto a vibrating ultrasonic transducer. The transducer converts electrical energy into high-frequency mechanical vibrations, generating intense ultrasonic waves.

As these ultrasonic waves propagate through the molten metal, they cause pressure fluctuations within the liquid, forming countless microscopic bubbles. These bubbles rapidly expand and collapse under the influence of the ultrasonic field, producing powerful shock waves and micro-jets — a phenomenon known as cavitation. The energy generated by cavitation induces strong disturbance and deformation on the molten metal surface. This surface instability causes the liquid stream to disintegrate into uniform fine droplets, which then rapidly cool and solidify into metal powder after leaving the ultrasonic transducer.

UA equipment is characterized by its compact size and simple structure, requiring minimal floor space and offering easy installation and operation. Maintenance costs are relatively low since the system mainly consists of the ultrasonic transducer and a few auxiliary components, which are reliable and durable, thus reducing maintenance frequency and costs. These advantages make UA equipment particularly suitable for environments with limited space or strict maintenance requirements.

UA systems are ideal for research environments, small-batch, and customized production. In R&D settings, where there is a need for rapid and flexible production of powders with varying compositions and properties, UA technology allows the quick preparation of high-quality metal powders, often within a single day. This enables researchers to obtain the required powder samples promptly, accelerating experimental and development progress.

For small-scale or customized production, UA technology also offers great flexibility and efficiency. It can be tailored to produce powders with specific compositions, particle size distributions, and morphologies according to customer requirements. The powders produced by UA typically feature high sphericity, excellent flowability, and a narrow particle size distribution. These properties ensure uniform filling and forming during subsequent processing and contribute to consistent product quality and improved performance stability.

In the atomization of precious metal alloys, UA equipment demonstrates unique economic advantages. For costly and rare metals such as silver, gold, and platinum, traditional atomization methods often lead to significant material waste, driving up production costs. UA systems, on the other hand, can rapidly produce high-quality powders while minimizing material usage and reducing waste, thereby improving cost efficiency.

For instance, in the jewelry industry, silver alloy powders produced via UA technology can be used in additive manufacturing to create intricate and delicate jewelry designs. Compared with traditional casting or machining methods, this approach not only offers greater design flexibility — enabling the production of more complex shapes — but also reduces material waste and lowers production costs. Moreover, the high quality and uniformity of UA-produced powders ensure that the resulting jewelry pieces exhibit superior surface finish, mechanical properties, and overall value.

3.5 Summary and Comparison of Atomization Technologies

Different atomization technologies exhibit distinct trade-offs in terms of cost, purity, and morphology control.
Water Atomization (WA) uses water as the disintegration medium, offering the lowest raw material and operating costs, making it suitable for large-scale, cost-sensitive production, such as conventional powder metallurgy parts and metal injection molding (MIM). However, WA powders typically have poor sphericity and a wide particle size distribution, limiting their use in applications requiring high powder quality.

Gas Atomization (IGA) occupies a mid-range cost level, capable of producing high-purity powders with good sphericity. It is widely used for general additive manufacturing and alloy production where powder quality is important. Nevertheless, its wide particle size distribution and satellite particle formation can lead to material losses and performance variability.

Plasma Atomization (PA) can produce ultra-spherical powders with a narrow size distribution and very low oxide content, ideal for reactive alloys (such as titanium) and critical LPBF applications. However, the high equipment investment and operating costs restrict its use in large-scale or cost-sensitive production environments.

Ultrasonic Atomization (UA) is best suited for research, small-batch, and customized production, capable of rapidly producing high-quality powders with narrow particle size distribution, offering economic advantages for precious metal processing. Its limited production scale, however, makes it less viable for mass industrial manufacturing.

When selecting an atomization technology, it is essential to balance factors such as application requirements, powder quality standards, and budget constraints to determine the most appropriate production process.

4.1 Particle Morphology Control (Sphericity)

In the metal powder manufacturing process, particle morphology—especially sphericity—plays a crucial role in determining powder performance. Powders with high sphericity exhibit excellent flowability because spherical particles experience less friction during movement, allowing them to flow smoothly through pipelines, containers, or processing equipment. In powder bed fusion additive manufacturing, good flowability ensures uniform powder spreading, preventing issues such as powder accumulation or voids, which could otherwise compromise the quality and precision of the formed parts. Poor powder flowability can lead to uneven powder layers, causing density and performance variations within the printed component. In severe cases, this may result in defects such as pores or cracks, ultimately affecting the mechanical properties and service life of the part.

Sphericity also significantly influences powder packing efficiency. Highly spherical powders can pack more densely in molds or powder beds, reducing void spaces between particles and improving packing efficiency. During the powder metallurgy compaction process, powders with high packing efficiency achieve greater density under the same pressure, thereby enhancing product strength and performance. Conversely, powders with poor sphericity, due to their irregular shapes, tend to form larger voids during filling, leading to lower packing efficiency and reduced product density and quality. In applications that demand high material density—such as aerospace engine component manufacturing—the sphericity and packing efficiency of the powder directly affect component performance and reliability, making precise control essential.

To achieve effective control of particle morphology, metal powder manufacturing equipment employs a range of advanced technologies and techniques. During atomization, the equipment uses inert gases or plasma to exploit surface tension during droplet formation and solidification, encouraging molten metal droplets to naturally form spherical particles. In inert gas atomization (IGA) systems, high-pressure inert gas interacts with the molten metal stream, breaking it into fine droplets. After droplet formation, surface tension causes the droplets to minimize surface area by assuming a spherical shape, while the inert gas atmosphere protects them from external interference during solidification, ensuring good sphericity.

Plasma atomization (PA) systems, on the other hand, use the high temperature and energy of a plasma torch to melt and atomize the metal into fine droplets. In this high-energy environment, surface tension effects are more pronounced, enabling rapid formation of spherical particles. Moreover, the intense energy of the plasma allows the droplets to solidify in an extremely short time, further ensuring particle sphericity and quality.

To address the common issue of satellite particles in gas atomization, advanced equipment is equipped with an “anti-satellite gas system.” This system introduces a specially designed gas flow field during atomization, adjusting gas velocity and direction to effectively reduce the adhesion of small particles to larger ones. By optimizing the gas flow, smaller particles are swiftly carried away before attaching to larger ones, thereby minimizing satellite formation and improving powder flowability and quality. The implementation of such systems has significantly enhanced the performance of gas-atomized powders, enabling them to meet the stringent powder quality requirements of advanced manufacturing applications.

4.2 Precise Control of Particle Size Distribution (PSD)

In metal powder manufacturing, particle size distribution (PSD) is a critical quality parameter that is precisely controlled by various operational factors. In gas atomization, the flow rate of the molten metal stream is one of the key factors influencing PSD. A lower molten metal flow rate allows the metal to interact more thoroughly with high-pressure inert gas, resulting in finer powder. When the flow rate decreases, less metal enters the atomization zone per unit time, enabling the high-pressure gas to act more effectively on the metal stream, breaking it into smaller droplets and ultimately producing powder with finer particle sizes.

In water atomization, the water pressure is decisive for controlling PSD. Higher water pressure generates more powerful water jets, which more effectively break the molten metal stream into finer droplets, producing finer powder. For example, increasing water pressure from 50 MPa to 100 MPa significantly increases the velocity and kinetic energy of the water jets, enhancing the impact force on the molten metal and allowing it to be fragmented into smaller droplets. By precisely adjusting operational parameters such as molten metal flow rate and water pressure, PSD can be effectively controlled to meet the specific particle size requirements of different applications.

PSD has a profound impact on all stages of additive manufacturing and on the final product quality. In laser powder bed fusion (LPBF) and similar additive manufacturing processes, PSD directly affects melt pool stability. An appropriate PSD ensures that the powder melts uniformly under the laser, forming a stable melt pool. Uneven particle size distribution may result in incomplete melting of some powder particles, creating defects in the melt pool and compromising the quality of the final part. Larger powder particles may not fully melt under the same laser energy, causing compositional inhomogeneity and negatively affecting the mechanical properties of the component.

PSD also significantly influences surface quality and part density. A narrower PSD can markedly improve the surface finish (Ra) of LPBF components. When particle sizes are more uniform, the powder layer spreads and melts more evenly, reducing surface roughness and defects. PSD also affects part density: an appropriate distribution allows powder to pack more densely, increasing the final part’s density. Conversely, an unsuitable PSD may cause loose packing, leading to internal porosity and reduced mechanical performance.

Optimizing PSD requires balancing multiple objectives to meet the demands of different processes and products. While the most spherical powder with the narrowest PSD may offer advantages in certain aspects, it is not always the optimal choice in practice. Because of the complex relationship between sphericity, PSD, and packing efficiency, equipment must be tuned to achieve a balance between maximum flowability (for rapid powder spreading) and adequate packing density (for material strength).

An excessively narrow PSD can reduce random packing efficiency. When particle sizes are almost identical, the powder tends to arrange in a more ordered structure, creating larger voids between particles and lowering packing density. To achieve multi-objective balance, modern equipment uses advanced control technologies and adjusts operational parameters to find the optimal PSD range. In gas atomization, this may involve optimizing high-pressure inert gas pressure and flow rate, adjusting molten metal flow rate and temperature, and using post-processing techniques such as classification or sieving to further refine the powder, producing a PSD that meets both flowability and packing density requirements.

4.3 Chemical Purity and Contaminant Management

High-purity metal powders are critical for ensuring the performance of the final products. In modern advanced manufacturing, many applications demand extremely high powder purity, such as in aerospace and medical fields. In aerospace, the purity of metal powders used for engine components directly affects engine performance and reliability. High-purity powders ensure that components can operate stably under harsh conditions, such as high temperatures and pressures, reducing the risk of material degradation and failure caused by impurities. In the medical field, metal powders used for implants must possess very high purity and biocompatibility to avoid adverse effects on the human body.

Low-purity metal powders can cause a range of serious problems. If powders contain significant amounts of interstitial elements like oxygen or nitrogen, these impurities may chemically react with the metal during subsequent processing or use, degrading material properties. Oxygen can oxidize the metal, forming an oxide layer that reduces conductivity and corrosion resistance, while nitrogen can lead to nitriding, altering the microstructure and mechanical properties. Impurities can also negatively affect powder formability and sintering behavior, potentially causing defects such as pores or cracks, which severely compromise product quality and service life.

To ensure high-purity metal powders, manufacturing equipment employs a series of effective control measures. Equipment integrates vacuum induction melting (VIM) with inert gas media to minimize oxygen and nitrogen content. In VIM, metal feedstock is melted in a vacuum environment, which effectively removes gaseous and volatile impurities, lowering oxygen and nitrogen levels. For example, in titanium alloy melting, the vacuum environment can reduce oxygen content to extremely low levels, enhancing the alloy’s purity and performance.

Inert gas media play a crucial protective role during atomization. In gas atomization, high-purity inert gases such as argon or nitrogen are used as both the atomization medium and protective gas. These gases form a protective layer around the molten metal droplets, isolating them from oxygen and nitrogen in the environment and preventing oxidation or nitriding during atomization and solidification. By precisely controlling vacuum levels and gas purity, the chemical purity of the metal powders can be effectively ensured, meeting the stringent quality requirements of high-end manufacturing.

At the microscopic level, contamination control relies on suppressing the oxidation of liquid metal. If the atomization medium is impure, residual oxygen or water vapor can react with the molten metal, forming metal oxides that create a surface oxide film. This oxide layer increases the viscosity of the molten metal, reducing flowability, hindering the formation of spherical particles, and producing rough powder surfaces that degrade performance.

To prevent such microscopic contamination, equipment optimizes the purity of the atomization medium and carefully controls the atomization environment. In gas atomization, high-purity inert gases are rigorously purified to remove oxygen, water vapor, and other impurities. Atomization nozzle design and gas flow fields are optimized to ensure that the inert gas uniformly envelops the molten droplets, forming an effective protective layer. This prevents oxygen and water vapor from contacting the molten metal, achieving effective contamination control at the microscopic scale and ensuring high-quality metal powders.

4.4 Post-Atomization Processing Procedures

5.1, Additive Manufacturing (AM/3D Printing)

In additive manufacturing (AM), commonly known as 3D printing, atomized metal powders play an indispensable role as the core material enabling technologies such as Direct Metal Laser Sintering (DMLS) and Laser Powder Bed Fusion (LPBF). Thanks to their unique physical and chemical properties, these powders make it possible to produce complex components with not only excellent mechanical performance but also intricate geometries that are difficult or impossible to achieve with traditional manufacturing methods.

In DMLS, atomized metal powders are selectively melted and sintered layer by layer under a high-energy laser beam to build a three-dimensional solid component. This manufacturing approach offers high design freedom, allowing the production of parts with complex internal structures, such as turbine blades for aerospace engines or customized geometries for medical implants. In LPBF, metal powders in the powder bed are selectively melted and solidified layer by layer according to pre-defined paths, forming precise three-dimensional shapes. This process demands powders with excellent flowability and precise particle size distribution to ensure uniform powder spreading and stable melting behavior, thereby guaranteeing the quality and accuracy of the final components.

Different types of alloy powders are widely used across AM in critical industries, including aerospace, medical, and energy electronics. In aerospace, nickel alloys are extensively employed to produce high-temperature turbine components, such as blades and disks, due to their superior high-temperature strength, oxidation resistance, and corrosion resistance. Components manufactured from nickel alloy powders via AM can withstand extreme operating conditions—high temperatures, pressures, and rotational speeds—ensuring efficient and reliable engine performance.

Titanium alloys, with their low density, high strength, and excellent biocompatibility, are used in aerospace to produce lightweight structural components, such as aircraft wings and fuselage frames, reducing aircraft weight and improving fuel efficiency and flight performance. In the medical field, cobalt-chromium and titanium alloys are commonly used for implants. Cobalt-chromium alloys offer wear resistance, corrosion resistance, and biocompatibility, making them ideal for hip and knee joint replacements. Titanium alloys, with superior biocompatibility and mechanical properties, are used for dental implants, spinal implants, and other medical devices, integrating well with human tissue to minimize rejection and extend implant lifespan.

In the energy and electronics sectors, copper alloys, with high electrical and thermal conductivity, are used for components such as heat exchangers and induction coils. Copper alloy powders produced via AM enable the fabrication of complex flow channel structures in heat exchangers, enhancing thermal efficiency and meeting the demands for high-performance thermal management in energy systems. In electronics, induction coils made from copper alloy powders improve electromagnetic induction efficiency, supporting the high-performance operation of electronic devices.

5.2, Traditional Powder Metallurgy (PM) and Metal Injection Molding (MIM)

In the field of traditional powder metallurgy (PM), water-atomized powders are an ideal choice for the mass production of PM components due to their low cost and high green strength. The irregular shape and high green strength of water-atomized powders allow mechanical interlocking between particles during powder compaction, forming dense structures that improve the density and strength of the green part. When manufacturing components such as valve seats and piston rings for automotive engines, water-atomized powders can meet the strength and wear-resistance requirements of these parts. At the same time, their cost advantage helps reduce production expenses and enhances the market competitiveness of the products.

Water-atomized powders are also widely used in industrial machinery component manufacturing. Through PM processes, they can produce parts of various shapes and sizes to meet the demands of different industrial sectors. After subsequent treatments like sintering, these parts achieve excellent mechanical properties, ensuring reliability and stability in practical applications.

Gas-atomized powders, with their superior flowability and compaction performance, play a crucial role in metal injection molding (MIM), particularly in the automotive and aerospace industries. In automotive manufacturing, many components require high precision, complex geometries, and excellent mechanical performance, such as fuel injection system parts and transmission gears. The good flowability of gas-atomized powders allows them to fill mold cavities smoothly during injection molding, forming precise shapes, while their excellent compaction performance ensures high density and strength in the molded parts, meeting the demanding operational requirements of automotive components under high-speed and complex conditions.

In the aerospace industry, component performance requirements are even more stringent, demanding lightweight, high-strength, and high-temperature-resistant properties. Components made from gas-atomized powders via MIM, such as small structural parts for aircraft engines and connectors for aerospace vehicles, can meet these demanding performance standards. Thanks to the high purity and excellent particle morphology of gas-atomized powders, the manufactured components exhibit superior quality and reliability, providing strong support for the safe operation of aerospace equipment.

5.3, Niche Market Applications

In niche markets, small atomizers specifically designed for precious metals, such as ultrasonic atomizers, demonstrate unique application value. Ultrasonic atomizers can economically atomize expensive and rare metal alloys, such as gold and platinum, meeting the demands of small-batch production. In the jewelry industry, additive manufacturing (AM) technologies, utilizing fine metal powders, have brought a transformative change to jewelry design and production. Compared with traditional casting and machining methods, AM offers remarkable design flexibility, enabling the creation of more intricate and exquisite jewelry designs.

By using precious metal powders produced with ultrasonic atomizers, jewelers can quickly create unique pieces tailored to individual customer requirements. This manufacturing approach also significantly reduces material waste and lowers production costs. When producing complex jewelry settings, traditional methods often generate substantial material scrap, whereas additive manufacturing allows precise control over material usage, maximizing efficiency and minimizing waste. This reduces the production cost of high-value jewelry while enhancing the market competitiveness of the final products.

Metal powder manufacturing equipment also plays a critical role in custom alloy production, meeting small-batch and specialized performance requirements. In industries such as electronics, medical, and research, there is often a need for alloys with specific properties, such as unique electromagnetic behavior, bioactivity, or high-temperature superconductivity. Metal powder manufacturing equipment can precisely control alloy composition and processing parameters to produce powders that meet these specialized performance requirements.

In electronics, some high-end devices require alloys with precise electrical properties. Metal powder manufacturing equipment can produce powders with high-precision resistivity, excellent conductivity, or specialized electromagnetic shielding performance by adjusting alloy composition and processing parameters. In the medical field, to meet personalized healthcare needs, implants with specific biocompatibility and mechanical properties must be produced. Metal powder manufacturing equipment can manufacture custom alloy powders, which can then be used in additive manufacturing to create personalized implants tailored to individual patients. This capability for customized production enables metal powder manufacturing equipment to provide effective solutions for the specialized needs of various industries, driving technological innovation and development across multiple sectors.

6.1 Major Equipment Suppliers and Technical Advantages

In the field of metal powder manufacturing equipment, numerous companies have established significant positions in the market through their advanced technologies and extensive experience. ALD Vacuum Technologies is a leading company in the industry, particularly distinguished for its vacuum inert gas atomizers (VIGA) and electrode induction gas atomization (EIGA) systems. The company offers customized VIGA and EIGA designs capable of handling up to 2,500 kg of charge material, meeting diverse customer demands for large-scale production and specialized processes. Its advanced technology and reliable equipment performance have earned it an excellent reputation in the production of high-purity metal powders, making it a preferred supplier for many high-end manufacturing enterprises.

Consarc is another manufacturer with strong technical capabilities, specializing in the development and production of large integrated systems. Its products excel in technologies such as vacuum induction melting inert gas atomization (VIM–IGA) and provide customers with comprehensive solutions from equipment design and manufacturing to installation and commissioning. Consarc’s equipment is widely used in aerospace, medical, and other industries with extremely high metal powder quality requirements, offering solid technical support for these sectors.

In addition to these large companies, some manufacturers focusing on specialized technologies are also emerging in the market. ATO/Amazemet, for example, leverages ultrasonic atomization technology to provide compact, flexible systems for research and small-batch production. These small-scale systems feature compact size, ease of operation, and high efficiency, meeting the needs of research institutions and small enterprises for precise, small-batch metal powder production, thus carving out a niche in specialized markets.

6.2 Future Development Trends

With the continuous advancement of technology, digitalization and automation have become key trends in the future development of metal powder manufacturing equipment. In the powder production process, digital technologies enable precise monitoring and control of critical process parameters. Through sensors and data acquisition systems, parameters such as pressure, flow rate, temperature, and gas purity can be obtained in real time and transmitted to the control system for analysis and processing. The control system automatically adjusts the operation of the equipment based on preset parameter ranges and algorithms, ensuring process stability and consistency. This precise parameter control effectively improves powder quality and reduces product defects caused by process fluctuations.

The application of automation systems significantly enhances production efficiency and scalability. Automated production lines can handle the entire process—from raw material feeding, melting, atomization, powder collection, to post-processing—without manual intervention, reducing labor intensity and minimizing human-related variability. Automation also enables continuous 24-hour production, greatly increasing output to meet large-scale manufacturing demands. In large metal powder manufacturing enterprises, the use of automated production lines has increased efficiency by several times while significantly improving product quality consistency.

The application areas of atomized powders are continuously expanding, showing great potential in emerging fields such as energy storage, advanced robotics, and next-generation electronic products. In energy storage, the rapid development of electric vehicles and renewable energy has driven a growing demand for high-performance battery materials. Atomized metal powders can produce battery electrode materials with high specific capacity, excellent conductivity, and cycling stability, offering new solutions to improve battery performance. By controlling powder particle size and morphology, the porosity and electronic transport properties of electrode materials can be optimized, enhancing charge-discharge efficiency and extending battery lifespan.

In advanced robotics, metal powder manufacturing equipment can produce high-strength, lightweight, and high-precision metal components that meet the demanding requirements of robots operating in complex environments. Through additive manufacturing, atomized metal powders can be used to create intricate robot joints and supports, improving flexibility and load-bearing capacity. The lightweight design of these components also reduces energy consumption and enhances operational efficiency.

In next-generation electronics, the demand for miniaturized, high-performance components drives the application of atomized powders. They can be used to manufacture highly conductive electronic circuits, miniature sensors, and RF devices, enhancing component performance and integration. When producing micro-sensors, the high precision and excellent formability of atomized powders enable the creation of smaller, more sensitive sensors, meeting the requirements for miniaturization and high performance in electronic products.

Conclusion