Simultaneous Efficient Fragmentation and Spheroidization: Cyclone Atomization Enables Defect-Free, High-Yield FeNi50...

FeNi50 powder production for metallic magnetic cores faces challenges including low fine-powder yield and defects like hollow particles. This study employed cyclone atomization to prepare FeNi50 powder and systematically examined the effects of atomization pressure (1-6 MPa) through combined simulation, experiment, and theoretical analysis. Results show that increasing pressure reduces the average particle size (D50) from 80.7 μm to 27.9 μm and raises the fine powder yield (-500 mesh) from 19.4% to 50.0%, far exceeding that of close-coupled nozzle atomization (<10%). The powder particles are spherical/near-spherical with dense, non-hollow interiors. Higher pressure also increases the cooling rate, which blurs surface grain boundaries, refines grain structure, and induces single-crystal or amorphous characteristics in particles < 15 μm while suppressing N and O absorption. X-ray diffraction confirms the phase composition remains unchanged. These evolutions originate from three synergistic mechanisms: competition between solidification and spheroidization times, centrifugal and Magnus forces from swirling flow, and plastic-state droplet deformation imparting specific surface roughness. Cyclone atomization therefore proves a promising method for producing high-quality FeNi50 powder, suitable for large-scale manufacturing of high-performance magnetic powder cores.