Plasma Atomization System

The atomization process uses metal wire as feedstock. The wire is fed coaxially into the induction plasma discharge, where it is heated until its tip melts. Once the melting point is reached, the hot plasma gases atomize the metal through a supersonic nozzle at the torch exit. Spherical particles are formed in-flight and directed downwards in a concentrated jet. The reactor is designed to allow particles to solidify before reaching the reactor bottom, preventing contact between the molten metal and any solid surfaces, thereby ensuring high powder purity. The resulting raw powder typically exhibits a particle size distribution up to 200 micron (μm) and specific cut sizes are obtained after classification according to end- use requirements. This technology produces a wide range of dense, spherical powders —including titanium and aluminum alloys — that have become a benchmark in additive manufacturing. Furthermore, the use of hot atomization gas, unlike conventional cold- gas atomization, minimizes the formation of satellite particles at the nozzle exit, where particle concentration in the gas stream is highest.