Aluminum-based spherical powders, made mainly by gas/water atomization, offer superior flow for additive manufacturing (AM), pigments, and energetic materials, with particle sizes from nano (sub-100nm) to hundreds of microns (e.g., 10-300 µm), and types include pure Al, Al-alloys (Mg, Si, Cu, Zn), and high-entropy alloys, essential for aerospace, electronics, and high-performance coatings due to their high density, purity, and controlled reactivity. 

Manufacturing Processes (for Spherical Powders)

Gas Atomization (Most Common): Molten Al/alloy is sprayed with inert gas (Ar, N2, He) jets, creating spherical particles.

Water Atomization: Uses water jets, typically produces irregular, rough flakes but can be modified.

Plasma Atomized Wire (PAW): Melts wire using plasma, yielding very clean, spherical powders (more costly).

VIGA (Vacuum Induction Melting Gas Atomization): High efficiency for various alloys.