Advancements in Understanding the Characteristics of Gas Atomized Powders: A Review

The morphology and particle size distribution (PSD) of atomized powder significantly affect the uniformity and flowability characteristics of the powder, and ultimately have a profound impact on the mechanical properties of additive manufacturing components. This article systematically reviews the key factors affecting powder particle size, deeply analyzes the formation mechanism and causes of defects, such as satellite particles, irregular particles, and hollow powders, and reveals the inherent relationship between powder particle size and sphericity. It should be noted that in the study of powder PSD, a systematic understanding with outstanding practical guidance value is summarized by integrating experimental observation data and numerical simulation results, however, further theoretical analysis is required to advance the fundamental understanding of this field. This discussion has important guiding significance for obtaining high‐quality atomized powders.