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Water atomization and gas atomization differ in the medium used to break up the molten iron. Water atomization uses a high-pressure water jet and produces particles with an irregular shape and a rougher surface, which improves green strength when the powder is pressed.

Gas atomization uses an inert gas such as nitrogen or argon and produces more spherical particles with higher flowability and lower oxygen pickup. Water-atomized powder is common for pressed and sintered parts, while gas-atomized powder is preferred where sphericity and flow are important, such as in metal additive manufacturing.

Particle shape affects how iron powder behaves at each stage of the powder metallurgy process. Irregular particles interlock when pressed, which gives the compacted part enough green strength to hold its shape before sintering. Rounder particles flow more freely and fill a die more evenly but bond less readily under pressure. Particle shape also influences the density and porosity of the finished part. For pressed and sintered components, an irregular atomized powder generally offers a good balance of compressibility and green strength.

Atomized iron powder is used across several industries. In powder metallurgy, it is pressed and sintered into structural parts, gears, and soft magnetic components. It also serves as a raw material in welding consumables, as a chemical catalyst, as a reducing agent in metal reduction reactions, and as an alloy additive in metal production. Additional uses include magnetic paints, resin casting, and metal-bonded diamond tools. It has also been used as an iron source in lithium-iron-phosphate battery chemistry. This range reflects the consistent purity and controlled particle size that atomized production provides.

It depends on the powder morphology and how it was atomized. Most metal additive manufacturing processes, such as laser powder bed fusion, require spherical and free-flowing powder with tight particle size control, which is typically produced by gas atomization.

Iron powder with an irregular particle shape is better suited to pressing and sintering than to most AM systems.  Atlantic Equipment Engineers offers dedicated additive manufacturing powders with controlled spherical morphology and particle size distributions matched to AM equipment. Buyers planning an AM build should contact our team to confirm the right iron powder for their process.

Atomized iron powder is available from Atlantic Equipment Engineers with a 2-pound minimum order. Standard bulk packaging is supplied in 50-pound and 100-pound pails, and smaller laboratory quantities are available for research and prototyping. Orders can ship by UPS or FedEx, and the product is stocked for immediate shipment. Custom packaging is available where an application calls for specific quantities or handling. Contact Atlantic Equipment Engineers to arrange packaging and quantities that match your requirements.

Atlantic Equipment Engineers supplies atomized iron powder for welding wires wholesale as well as for coated electrode production. In flux-cored and metal-cored welding wires, iron powder is added to the core to raise deposition rates and improve weld metal recovery. Atlantic Equipment Engineers stocks the powder at 98% minimum purity and a -325 mesh particle size and can supply it in bulk pail quantities for consumable manufacturers. Contact us to discuss volume pricing and packaging for wholesale welding wire production.