Atomization is the process of turning molten metal into fine powder — the first and most fundamental step in the MIM supply chain. Four main technologies exist, each producing powder with different characteristics.
Atomization methods compared:| Method | How It Works | Particle Shape | D50 Range | Oxygen | Cost Index |
|---|---|---|---|---|---|
| Water atomization | High-pressure water jets break up molten metal stream | Irregular / angular | 5-25 µm | 0.2-0.5% | 1.0x |
| Gas atomization | Inert gas (Ar, N₂) breaks up molten stream | Fully spherical | 10-30 µm | < 0.1% | 1.5-1.8x |
| Plasma atomization | Plasma torch melts wire; centrifugal atomization | Highly spherical, very clean | 15-45 µm | < 0.05% | 3-5x |
| Water-gas combined (ATMIK) | Water primary + gas secondary for spheroidization | Near-spherical | 10-20 µm | 0.08-0.15% | 1.2-1.3x |
- Water atomization: Most common for MIM — low cost, high fine-fraction yield (70-85% below 20 µm). Limited to applications where 0.2-0.5% oxygen is acceptable. Best for general-purpose 316L, Fe-2Ni, and low-alloy steel parts
- Gas atomization: Premium spherical powder with lowest oxygen. Used for medical implants, aerospace components, and thin-wall parts requiring maximum flowability. Higher cost but delivers 1-2% higher sintered density
- Plasma atomization: Highest purity, most spherical. Used primarily for reactive metals (titanium, tantalum) where oxygen control is critical and cost is secondary. Common in the medical implant industry
- Water-gas combined: ATMIK's proprietary technology — provides near-gas-atomized quality at closer-to-water-atomized cost. Delivers spherical powder with controlled oxygen (0.08-0.15%) and high fine-fraction yield
Atomization is the process of breaking up molten metal into fine powder particles using high-pressure water, inert gas, or plasma. Water atomization is the most common and cost-effective but produces irregular particles with higher oxygen. Gas atomization produces spherical, low-oxygen powder at higher cost. Plasma atomization produces the highest-purity powder for titanium and reactive metals. ATMIK's proprietary water-gas combined atomization bridges the gap, delivering near-spherical particles at moderate cost.