A new atomization process, plasma atomization (P.A.), has been develop
ed to produce fine, spherical powders. Unlike conventional high-pressu
re atomizers, P.A. utilizes multiple nontransferred direct-current arc
plasmas to accelerate the atomization gas. In the P.A. process, metal
wires are fed into the apex of the multiple plasmas, where they melt
and are atomized in a single step. This process offers the unique abil
ity to produce spherical powders of reactive metals with atypical aver
age particle size of 40 mu m.