The paper is concerned with the production of ultrafine aluminium alloy powder by the relatively novel route of gas atomization at high pressures (4–8 MPa). It is shown that such a process is capable of the bulk production of rapidly solidified alloy powder having a median diameter below 20 μm. Some process variables are discussed and preliminary results obtained from the operation of a high pressure gas atomizer at the University of Surrey are presented. In addition, some results concerning the consolidation behaviour of such rapidly solidified powder are discussed. PM/0371
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