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Volume 113
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Effect of over-pressure on size distribution and morphology of copper powder produced by gas-atomization
Niraj Kumar a, Supriya Sarkar b, T.N.C. Anand c, Shamit Bakshi a *
a Department of Mechanical Engineering, Indian Institute of Technology Madras, Chennai, India
b Alleima India Pvt. Ltd., Pune, Maharashtra, India
c Department of Mechanical Engineering, Indian Institute of Technology Palakkad, Kerala, India
10.1016/j.partic.2026.03.025
Volume 113, June 2026, Pages 298-311
Received 14 January 2026, Revised 5 March 2026, Accepted 19 March 2026, Available online 1 April 2026, Version of Record 8 April 2026.
E-mail: shamit@iitm.ac.in
Highlights

• Over-pressure affects the size distribution and morphology of copper powder.

• Particle size (d50) of the powder increases with over-pressure.

• Sphericity, smoothness and flowability of the particles improved with over-pressure.

• Yield of coarse particles increases with over-pressure.


Abstract

Copper powder is widely used in several industrial applications where specific particle size ranges and morphological characteristics are required. In this study, a systematic experimental investigation was carried out to examine the influence of over-pressure applied to the molten metal and atomizing gas flowrate on the particle size distribution, spread, morphology, flowability, and yield of gas-atomized copper powder using an over-expanded condition for the atomizer exit. It is seen that the over-pressure plays a critical role in governing not only the mass median diameter (d50) but also particle morphology, spread of the particle size distribution, and flow performance. For a fixed gas flowrate, increasing over-pressure results in coarser particles with improved sphericity in terms of lesser satellite formation, smoother surface, and enhanced flowability. The combined effect of over-pressure and gas flowrate on particle size spread and application-specific size windows was quantitatively established. High-speed visualization further revealed that variations in over-pressure influence melt stream stability and undisturbed jet length. The findings show that optimized combinations of higher gas flowrate and lower over-pressure improve powder yield within industrially relevant size ranges. Overall, this study provides mechanistic insight and practical guidance for tailoring copper powder characteristics through controlled adjustment of over-pressure and gas flowrate.

Graphical abstract
Keywords
Gas-atomization; Over-pressure; Gas-to-metal ratio (GMR); Yield; Mass median size (d50); Flowability
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