Gas atomization for metal powder production in additive manufacturing: A review

Abstract

Gas atomization is a key technology for producing high-quality metal powders, widely adopted in additive manufacturing and other powder-based industries due to its versatility and productivity. Its complexity, such as intense gas–liquid momentum exchange, thermal gradients in solidification, and multiple influencing factors, poses significant challenges for process control. This comprehensive review explores the complexities of gas atomization technology in metal powder production, examining the underlying mechanisms, simulation techniques, flow field dynamics, and key influencing factors. It clarifies that primary atomization is characterized by liquid film atomization, driven by Kelvin–Helmholtz instabilities, and fountain atomization, triggered by Rayleigh–Taylor instabilities. Secondary atomization, on the other hand, is predominantly influenced by shear and inertial forces. The review emphasizes the key roles of physical gas and liquid properties, temperature, pressure, nozzle design, and solidification processes in determining the characteristics of the resulting metal powder. It concludes that a thorough understanding of these factors is essential for refining the atomization process and improving the quality of the metal powder produced. The review suggests that future research should focus on resolving discrepancies in atomization mechanisms, enhancing simulation methodologies, and investigating the effects of advanced nozzle designs on the production of metal powder.