Gasatomized

Gas atomized refers to a method of producing metal powders by atomizing molten metal with a high-velocity jet of inert gas. The process yields largely spherical particles that are shielded from oxidation by the protective gas, making gas-atomized powders suitable for demanding applications such as additive manufacturing, powder metallurgy, and surface coatings.

In operation, molten metal is delivered into a nozzle or crucible where it is disintegrated by a jet of inert gas, typically argon or nitrogen. The gas shear breaks the liquid metal into droplets, which then solidify into spherical particles within the protective atmosphere. The gas choice and process conditions influence contamination levels, oxide formation, and the resulting particle morphology. Gas atomization generally produces powders with good flowability and a narrow particle size distribution compared with some alternative methods.

Materials commonly produced by gas atomization include aluminum and its alloys, stainless steels, nickel-based superalloys, titanium and its alloys, copper alloys, and some refractory metals. Particle sizes for gas-atomized powders vary by alloy and specification, typically spanning tens of micrometers to a few hundred micrometers, with finer grades used for additive manufacturing and coarser grades for powder metallurgy applications.

Advantages of gas atomization include high sphericity, low surface oxides, and consistent flow properties, which support high packing density and reliable performance in processes such as laser or electron beam melting. Limitations include higher equipment and operating costs and potential gas-related inclusions if process controls are inadequate. Gas-atomized powders are widely used in metal additive manufacturing, hot isostatic pressing, and coatings, where powder quality directly affects density, mechanical properties, and finish. Quality control focuses on particle size distribution, flow behavior, apparent density, and chemical composition.