There are a number of process parameters which affect the characteristics of metal powders produced by free fall gas atomization. In the following work effects of various process parameters like apex angle of atomizer, focal length of atomizer, number of nozzles, diameter of nozzles, diameter of liquid metal delivery tube, superheat of liquid metal and type of metal etc. were studied on their surface morphology. It was observed that shape of powder particles depends on apex angle, superheat of liquid metal, type of metal and particle size range within a powder collective. Other parameters like focal length of atomizer, number of nozzles, diameter of nozzles and diameter of liquid metal delivery tube were found to have no effect on the shape of powder particles. However, Surface porosity and solidification shrinkage were observed on almost all types of metal powders. (c) 2006 Springer Science + Business Media, Inc.