Spherical monosized pure aluminum (Al) particles are successfully fabricated by the pulsated orifice ejection method (POEM). The surface reaction between Al and the graphite crucible is investigated by analysing the microstructure and chemical composition of the materials. No significant chemical reaction occurs between Al and the graphite owing to the crystalline Al oxide (γ-Al2O3) layer generated in the initial state. The γ-Al2O3 layer is clearly observed in all regions between the Al particles and graphite via transmission electron microscopy and confirmed by the selected area diffraction pattern. The morphology of the γ-Al2O3 layer perfectly follows the surface morphology of the graphite crucible, which showed nanoscale roughness. This implies that molten Al could not directly contact graphite even though the surface of the crucible became rough to some extent. However, this passivation phenomenon allowed the successful fabrication of monosized pure Al particles. Therefore, POEM is a useful process at least to manufacture monosized pure Al particles.

Monosized germanium micro particles are prepared by a newly developed Pulsated Orifice Ejection Method. The obtained particles are categorized into two kinds of the microstructures as refined and coarse ones. The morphological difference is estimated to be determined by the undercooling level during nucleation. Actually, the increase in the temperature of the melt was effective in coarsening the microstructure, because the temperature of the melt intensely relates to the undercooling level. The transition temperature of coarse and refined microstructures is found to be 1300-1350K. Furthermore, a triggered nucleation could improve the crystallinity of the particles in the short separation.

Mono-sized silicon particles were effectively fabricated by a novel way named pulsated orifice ejection method (POEM). The particles are with very narrow particles size distribution and very small standard deviation of mean particle size. There are two different types spherical silicon particles were found. One consists of many grains mainly in random boundaries. The other consists of two or three grains with only twin orientation relationships, even single crystal in cross-section was also found within this type of spherical silicon particles.