Plasma spheroidization utilizing a plasma spray gun has been demonstrated for water-atomized stainless steel SUS316L powder. The angular particles were successfully spheroidized, and the D50 size of particles were decreased from 35 μm to 24 μm with 9 kW of processing power and to 15 μm with 17 kW of processing power. It was found that the high processing power of 17 kW generates a significant number of fine particles with the size of under 1 μm. By contrast, the powder formed on low processing power of 9 kW has better flow-ability and low cohesiveness, suggesting that an appropriate processing power exists to form the spherical powder suited for additive manufacturing

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