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Commercially available aluminium powder has been processed in a thermal plasma jet. The processed powder has been characterized by scanning electron microscopy (SEM) for particle size and morphology. Particle size distribution has been determined by laser scattering technique. Results show that, in contrast to the irregular shapes of the particles of the raw material, majority of the processed powder particles bear spherical or near-spherical morphology. The spherical morphology without sharp edges and corners and particle size distribution in a narrow range ensures free flow of the powder through the powder feed lines, and better spray efficiency, making it ideal for thermal spray applications.

Particle morphology and size distribution of plasma processed aluminium powder