Properties of the powders developed during atomization process are essentially determined by process parameters. Experiments based on splat collection have been performed at different stages of the process evolution. Formation of splat formed as a result of impingement of the melted metallic droplets onto a substrate was studied. Splat characteristics have been determined from image analysis in function of process parameters and time progress. Droplet diameters were measured using laser Coulter analyzer. Direct relationships between splat diameter and droplet diameter were established. The atomization experiments point out the strong influence of two processing parameters (atomizing gas and melt nozzle diameter) on splat characteristics and particle size. It has been observed that increasing atomizing pressure leads to a decrease of mean splat diameter and width of the size distribution. Similar evolution was found for droplet diameter. Moreover, it is clearly shown that increasing melt nozzle diameter induces an increase of both splat diameters and droplet diameters. The results provide a better understanding of the influence of atomization parameters on the size distribution. (C) 2012 Elsevier B.V. All rights reserved.