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Superalloy powders, which have a small particle size and spherical shape, were prepared by a spark plasma discharge process. The electrical parameter, spark voltage, current and pulse duration have very important effects on the size distribution of produced superalloy powders. When current or pulse duration changed the mean size significantly changed.

Superfine and nano-sized Fe powders were prepared by a spark plasma discharge process in deionized water. The powders were characterized by Field Emission Scanning Electron Microscope (FESEM) with Oxford Inca EDX, and X-ray diffraction (XRD). The experimental results indicate that the powders prepared by the process have a bimodal size distribution, high purity, single phase, good spherical shape and high yield.