In this study, AlSi10Mg alloy powders are synthesized using gas atomization and sieving processes for powder bed fusion (PBF) additive manufacturing. The effect of nozzle diameter (ø = 4.0, 4.5, 5.0 and 8.0 mm) on the gas atomization and sieving size on the properties of the prepared powder are investigated. As the nozzle diameter decreases, the size of the manufactured powder decreases, and the uniformity of the particle size distribution improves. Therefore, the ø 4.0 mm nozzle diameter yields powder with superior properties. Spherically shaped powders can be prepared at a scale suitable for the PBF process with a particle size distribution of 10–45 μm. The Hausner ratio value of the powder is measured to be 1.24. In addition, the yield fraction of the powder prepared in this study is 26.6%, which is higher than the previously reported value of 10–15%. These results indicate that the nozzle diameter and the post-sieve process simultaneously influence the shape of the prepared powder as well as the satellite powder on its surface.

In this study, p-type : TAGS-85 compound powders were prepared by gas atomization process, and then their microstructures and mechanical properties were investigated. The fabricated powders were of spherical shape, had clean surface, and illustrated fine microstructure and homogeneous + GeTe solid solution. Powder X-ray diffraction results revealed that the crystal structure of the TAGS-85 sample was single rhombohedral GeTe phase, which with a space group . The grain size of the powder particles increased while the micro Vickers hardness decreased with increasing annealing temperature within the range of 573 K and 723 K due to grain growth and loss of Te. In addition, the crystal structure of the powder went through a phase transformation from rhombohedral () at low-temperature to cubic () at high-temperature with increasing annealing temperature. The micro Vickers hardness of the as-atomized powder was around 165 Hv, while it decreased gradually to 130 Hv after annealing at 673K, which is still higher than most other fabrication processes.

Fe based (FeCSiBPCrMoAl) amorphous powder, which is a composition of iron blast cast slag, were produced by a gas atomization process, and sequently mixed with ductile Cu powder by a mechanical ball milling process. The Fe-based amorphous powders and the Fe-Cu composite powders were compacted by a spark plasma sintering (SPS) process. Densification of the Fe amorphous-Cu composited powders by spark plasma sintering of was occurred through a plastic deformation of the each amorphous powder and Cu phase. The SPS samples milled by AGO-2 under 500 rpm had the best homogeneity of Cu phase and showed the smallest Cu pool size. Micro-Vickers hardness of the as-SPSed specimens was changed with the milling processes.

The spherical and high quality Titanium fine powder "Tilop" has been produced with gas atomization furnace, Sumitomo Titanium Corporation originally designed. Recently, a new process which can produce Ti-alloy(Ti-6Al-4V) powders by utilizing our gas atomization process, of which raw material is sponge titanium pre-mixed with alloy chips or granules has been also developed. The particle size of gas atomized Ti-alloy powder and the mechanical properties of sintered Ti-alloy compacts prepared by metal injection molding were discussed in this study.

In order to improve mechanical properties, the hypereutectic Al-20 wt%Si based prealloy powder was prepared by gas atomization process. Microstructure and compressibility of the atomized Al-Si powder were investigated. The average powder size was decreased with increasing the atomization gas pressure. Size of primary Si particles of the as-atomized powder was about . The as-atomized Al-Si powder such as AMB 2712 and AMB 7775 to increase compressibility and sinterability. Relative density of the mixed powder samples sintered at was reached about 96% of a theoretical density.