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resistance due to the stability of the oxide films that form spontaneously on the surface. The addition of precious metals such as Pd, Ru and Pt can further increase the corrosion resistance of metals and alloys, including alloys systems such as Fe-Al and stainless steels (Mwamba, Cornish and van der Lingen, 2014; Couperthwaite, 2015; Olubambi, Potgieter and Cornish, 2009), but at increasing cost. In recent years the manufacturing landscape has changed significantly with an emphasis on developing technologies to manufacture components costand resourceefficiently on a small scale (Williams and Revington, 2010), making this technology suitable for expensive powders containing precious metals. The emergence of additive manufacturing (AM) heralds a technology where value chains are shorter, smaller, localised and more collaborative (Ford and Despeisse, 2016). One of these new technologies used to manufacture high-quality components is direct laser sintering, or 3D printing. The powders required for these methods have to be spherical and of a narrow particle size distribution as this affects the packing density and sintering mechanism. The powder also has to be chemically pure, as impurities such as H, O, C, N and S causes brittleness, influence metal properties such as tensile strength, hardness and ductility and also increase surface tension during processing (Despa and Gheorghe, 2011). More conventional techniques which can also reduce cost where materials are expensive include layer deposition methods such as thermal spraying (Wrona et al., 2017). Thermal spraying methods such as plasma spraying, however, require a powder with excellent flowability and high apparent density to produce dense coatings (Qian, Du and Zhang, 2009). In this regard, spherical powders present optimum flowability and density. Thermal plasmas, characterised by their extremely high temperatures (3000–10 000 K) and rapid heating and cooling rates (approx. 106 K/s) under oxidizing, reducing or inert conditions, are particularly suitable for spheroidisation of metal and alloy powders with relatively high melting points. Residence times of particles in the plasma region range from 5 to 20 ms, but this is usually sufficient as 7 to 8 ms is required for heating and melting of metal particles in the 30–50 μm size range at 3500 K. A radio-frequency (RF) plasma is the preferred plasma method due to the longer residence time, larger plasma volume and the lower risk of contamination as no electrode erosion occurs (Grignard, 1998). TEKNA Plasma Systems Inc. is one of the companies that supplies high-temperature plasma technology equipment for various applications, including plasma spheroidisation. Metal and alloy spheroidisation for the Advanced Metals Initiative of South Africa, using high-temperature radiofrequency plasmas

Metal and alloy spheroidisation for the Advanced Metals Initiative of South Africa, using high-temperature radio-frequency plasmas