This work explores the innovative technology of ultrasonic atomization by employing metal powder-cored wire as a filament to fabricate spherical powders for powder-based metal additive manufacturing. The method demonstrates a novel approach to generate uniform size distributions of spherical-shaped powders in the range of 30-60 mkm, characterized by a homogeneous composition of aimed high-entropy alloy. This technique's significance lies in its ability to efficiently produce High Entropy Alloy (HEA) powder, marking a substantial stride toward energy-efficient routes in material fabrication.  Spherical powder was produced and analyzed for physical and mechanical properties. Further on, powder processability using powder bed fusion – laser beam was studied. The implications extend across multiple industrial sectors, promising new way for advanced materials synthesis and manufacturing processes.
Keywords: Atomization, metal powder-cored wire, high entropy alloy, spherical powder, ultrasonic atomization