A gas atomizer is a device used to disperse a stream of molten metal into fine powder particles. Understanding and optimizing the atomization of metal powders are essential steps to enhance the quality and performance of AM-produced components. The breakup of the molten metal can be divided in two stages, primary and secondary atomization. In the primary stage, the liquid jet disintegrates into ligaments and larger droplets. The secondary breakup involves the fragmentation of these larger droplets into finer particles. In this secondary stage, the droplet breakup to fine particles and then cools down to solid state before reaching the bottom of the atomization chamber.