It is provided an assembly for atomizing a metal melt, comprising a target element to which the metal melt can be supplied for atomization, wherein the target element is additively manufactured. It is further provided a method for producing an assembly, a method for atomizing a melt of metal to powder, and a device for producing metal powder.

An alloy represented by the formula (Mn.sub.xAl.sub.y)C.sub.z, the alloy being aluminum (Al), manganese (Mn), and carbon (C), and optionally unavoidable impurities; wherein x=56.0 to 59.0 y=41.0 to 44.0 x+y=100, and z=1.5 to 2.4. The alloy is highly suitable for forming the and phase in high purity and high microstructural homogeneity. A method for processing an alloy of formula (Mn.sub.xAl.sub.y)C.sub.z, wherein x=52.0 to 59.0, y=41.0 to 48.0, x+y=100, and z=0.1 to 3.0, the process including providing the raw materials of the alloy, melting the raw materials, and forming particles of the alloy by gas atomization of the molten alloy.

An alloy represented by the formula (Mn.sub.xAl.sub.y)C.sub.z, the alloy being aluminum (Al), manganese (Mn), and carbon (C), and optionally unavoidable impurities; wherein x=56.0 to 59.0 y=41.0 to 44.0 x+y=100, and z=1.5 to 2.4. The alloy is highly suitable for forming the and phase in high purity and high microstructural homogeneity. A method for processing an alloy of formula (Mn.sub.xAl.sub.y)C.sub.z, wherein x=52.0 to 59.0, y=41.0 to 48.0, x+y=100, and z=0.1 to 3.0, the process including providing the raw materials of the alloy, melting the raw materials, and forming particles of the alloy by gas atomization of the molten alloy.

An example system includes at least one acoustic sensor configured to generate at least one time-dependent acoustic data signal indicative of an acoustic signal generated by an atomization system performing a process possessing a plurality of process attributes, and a computing device including an acoustic data signal processing module configured to receive the at least one time-dependent acoustic data signal, and transform the at least one time-dependent acoustic data signal to a frequency-domain spectrum, wherein each process attribute of the plurality of process attributes is associated with at least one respective frequency band, and a correlation module configured to determine a process attribute of the plurality of process attributes by identifying at least one characteristic of the frequency-domain spectrum.

A preparation process for preparing powder from a first material and a second material, having: a step of dispensing wires made of the materials by means of a feeder and an additional feeder, a melting step of melting the wires, a spraying step of spraying in such a way as to form droplets, a cooling step of cooling the droplets in such a way as to form solid particles, a separation and collection step of separating the solid particles from the carrier gas and collecting the solid particles so as to form the powder, and, during the dispensing step, the wires are firstly pushed by the feeder, then pulled by the additional feeder, and then pushed by the additional feeder towards said electric arc.

A preparation process for preparing powder from a first material and a second material, having a step of melting the first and second materials using an electric arc, a step of spraying the first and second molten materials in such a way as to form droplets, a step of cooling the droplets using a carrier gas so as to form solid particles, and a step of separating the solid particles from the carrier gas and collecting the solid particles so as to form the powder, the electric current applied to form the electric arc being a short circuit current.

An alloy composition includes 40-60 wt. % of a nickel-based superalloy and 40-60 wt. % of a cobalt-based superalloy based on the total weight of the alloy composition. The nickel-based superalloy includes 40-60 wt. % of nickel and 15-25 wt. % of chromium based on the total weight of the nickel-based superalloy. The cobalt-based superalloy includes 50-70 wt. % of cobalt and 25-35 wt. % of chromium based on the total weight of the cobalt-based superalloy. The nickel-based superalloy and the cobalt-based superalloy are homogeneously distributed in the alloy composition. Further, the alloy composition is a spark plasma product of spherical particles having an average particle size of 10 micrometers (m) to 45 m of the nickel-based superalloy and particles having an average particle size of 5-40 m of the cobalt-based superalloy. The alloy composition is more corrosion-resistant than a pure nickel-based superalloy and a pure copper-based superalloy.