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REVIEW ARTICLE

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

Chaocai Zhang1,2 ,  Fuzhong Chu3 ,  Zongyan Zhou1,2,3*
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1 Jiangxi Provincial Key Laboratory of Particle Technology, Jiangxi University of Science and Technology, Nanchang, Jiangxi , China
2 Research Centre for Intelligent Mineral Processing & Metallurgy, International Institute for Innovation, Jiangxi University of Science and Technology, Nanchang, Jiangxi , China
3 ARC Research Hub for Smart Process Design and Control, Department of Chemical and Biological Engineering, Faculty of Engineering, Monash University, Melbourne, Victoria , Australia
MSAM, 026220051 https://doi.org/10.36922/MSAM026220051
Received: 31 May 2026 | Revised: 31 July 2026 | Accepted: 5 August 2026 | Published online: 1 September 2026
© 2026 by the Author(s). This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution 4.0 International License ( https://creativecommons.org/licenses/by/4.0/ )
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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.

Keywords
Gas atomization
Mechanisms
Simulation
Flow field characteristics
Funding
None.
Conflict of interest
The authors declare they have no competing interests.
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