Process for producing spheroidized powder from feedstock materials

A method for manufacturing a spheroidized powder having a desired particle size distribution between about x and about y, wherein x represents a low end of the particle size distribution and having a value of 5 microns and y represents a high end of the particle size distribution and having a value of 45 microns, the method comprising:

• introducing metallic particles obtained by milling or crushing scrap metal or used metal parts into a microwave plasma torch, a majority of said introduced metallic particles having a volume between about 4/3π(x/2)3 and about 4/3π(y/2)3, and wherein said introduced metallic particles having at least one of a collective average or median aspect ratio between 2:1 and 200:1;
• and
• melting and spheroidizing the metallic particles within the microwave plasma torch to form spheroidized powder having the desired particle size distribution of about x to about y;
• wherein the scrap metal or used metal parts comprise a work hardened microstructure that is retained in the spheroidized powder after applying the microwave plasma process.