Plasma atomization metal powder manufacturing processes and systems thereof

A plasma atomization metal powder manufacturing process comprising:

• providing a heated metal source at a feed rate from 8 to 13 kilograms per hour;
• contacting said heated metal source with an atomizing gas of at least one plasma source under conditions effective for causing plasma atomization of said heated meal source, wherein said plasma atomization is carried out by using a total gas to metal ratio of greater than 0 and less than or equal to 17;
• and
• obtaining, from said plasma atomization, a raw metal powder having a particle size distribution yield of at least 80% in a range that is greater than 0 μm and up to 106 μm, measured according to ASTM B214-07 (2011);
• wherein the heated metal source is Ti-6Al-4V,
• wherein said heated metal source is a wire or a rod heated by resistive heating, arc discharge, induction heating, or a combination thereof prior to contacting the atomizing gas.