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This study experimentally investigates the effect of temperature on the size and shape of the AZ31 alloy powder made by the gas atomization method. A constant nozzle diameter of 2mm was used during the tests at a gas pressure of 35 bar and three different temperatures of 790, 820, and 850°C. Argon gas was used for the atomization of the melt while the shape of the powder produced was determined by scanning electron microscopy (SEM). In addition, XRD and XRF analyses were adopted to determine the phases of the powders' internal structure as well as the percentages of each phase. Furthermore, a laser-assisted measurement device was utilized for powder size analysis. The results revealed that most of the AZ31 alloy powders got into flake and spherical forms and few in the form of ligaments, rods or droplets depending on the temperature. Moreover, the finest powder was obtained at a temperature of 790 °C with powder shape of both droplet and spherical.
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