Research and application status of plasma rotating electrode process technology in additive manufacturing

Performance metal powder serves as a crucial material in 3D printing additive manufacturing， as the properties of the powder directly influence the microstructure and overall performance of 3D-printed components. The plasma rotating electrode process （PREP） employs high-temperature plasma to melt the end face of a rapidly rotating electrode rod. Subsequently， the molten liquid film is fragmented into droplets， which then solidify into powder under the action of centrifugal force. This paper provides a comprehensive review of the development history， equipment types， powder preparation principles， and performance characteristics of the PREP process. It also delves into the impact of process parameters on the powder's properties and discusses the application of numerical simulation methods in understanding the powder formation mechanism and controlling powder particle size. Furthermore， the paper reviews the progress made in applying PREP-prepared powder materials in the 3D printing manufacturing of aerospace， medical equipment， nuclear power， rail transit， and other equipment sectors. Finally， it is highlighted that the PREP milling process is poised to evolve towards higher purity， finer particle size， narrower particle size distribution， fewer inclusions， higher sphericity， greater efficiency， and lower costs.