Review on preparation technology and properties of spherical powders

With the continuous evolution of additive manufacturing technology, the production of spherical powders has become increasingly vital. Various studies suggest that factors such as the preparation process, powder materials, and sphericity are crucial in determining product performance. This paper provides a comprehensive review of the principles, advantages, and disadvantages of three widely used preparation technologies for spherical powders: gas atomization (GA), plasma rotating electrode process (PREP), and radio frequency plasma (RFP). Next, we identify the current research gaps in the preparation process for spherical powders and analyze the techniques for controlling particle size, sphericity, and purity during powder production. Finally, we proposed the development trend of spherical powder preparation technology, which provides crucial insights for optimizing the preparation process.