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We have studied the formation of Pd 42.5 Cu 30 Ni 7.5 P 20  metallic glass droplets and wires in the gas atomization process. We demonstrate that the sizes of droplets and wires can be distinguished by the Ohnesorge number ( O   h  ), which is the proportion of the spinnability to the capillary instability, and the diameter distributions follow a log-normal distribution function, implying cascade fragmentation. For droplets, the number significantly increases at  O   h   < 1 but the diameter gradually decreases. For wires, the number greatly increases at  O   h   > 1 while the diameter steadies below 400 nm. Further, the wire diameter is quadrupled at  O   h   = 16 due to the high viscosity which suppresses both capillary breakup and ligament elongation.

Log-normal diameter distribution of Pd-based metallic glass droplet and wire