Process and apparatus for producing powder particles by atomization of a feed material in the form of an elongated member

A process for producing powder particles by atomization of a feed material in the form of an elongated member, using an inductively coupled plasma torch including a longitudinal axis, a coaxial injection probe at a first end of the plasma torch and comprising an elongated conduit which extends through at least an upper portion of a coaxial plasma confinement tube, and an atomization nozzle comprising a coaxial aperture for the elongated member at a second end of the plasma torch opposite the first end, said process comprising:

• introducing the elongated member into the plasma torch through the coaxial injection probe;
• moving the elongated member axially in the plasma torch through the coaxial injection probe and from the coaxial injection probe to the coaxial aperture of the atomization nozzle;
• producing at least one feed material atomizing plasma jet by supplying plasma from the plasma torch to the atomization nozzle;
• and
• surface melting and atomizing feed material of a forward end of the elongated member by exposure to the at least one feed material atomizing plasma jet produced by the atomization nozzle.