低熔点锌基合金在激光粉末床熔融(LPBF)过程中蒸发飞溅严重，导致成形质量下降，优化粉末形貌和粒径是改善这一问题的有效措施。本工作通过电极感应气体雾化(EIGA)和等离子旋转电极(PREP)方法制备了2种具有不同形貌和粒径的Zn-Mn-Mg合金粉末，并采用LPBF技术制备合金块体，比较了2种粉末的成形工艺窗口，研究了粉末形貌和粒径对LPBF制备锌合金微观组织和力学性能的影响。结果表明，由 PREP方法制备的粉末具有更优的球形度和较大的粒径，相较于EIGA方法制备的粉末，其在 LPBF过程中表现出更宽的优质成形工艺窗口成形。在最优的LPBF成形工艺参数下，PREP方法制备的粉末所得成形锌合金块体具有更致密的微观组织和更小的晶粒尺寸。成形的2种块体试样的拉伸屈服强度(约210 MPa)和抗拉强度(约285 MPa)无显著差异，但EIGA + LPBF制备的块体试样的压缩屈服((288.2 ± 4.3) MPa)略高于PREP + LPBF制备的块体试样((258.5 ± 3.5) MPa)。PREP + LPBF方法制备的块体试样拉伸延伸率(21.8% ± 2.3%)显著高于EIGA + LPBF方法制备的块体试样(3.3% ± 0.7%)，塑性差异可能归因于PREP方法制备粉末在LPBF过程中具有更均匀的热传导和应变分布。

Zinc-based alloys are emerging as the next generation of degradable metals due to their favorable degradation rates. Additive manufacturing offers the capability to produce personalized structures, making it a promising method for generating biomedical metal components. However, during laser powder bed fusion (LPBF), zinc-based alloys can experience significant evaporation because of their low melting point, which often results in poor surface quality. Optimizing powder morphology and particle size presents a potential strategy to enhance forming quality. In this study, two Zn-1Mn-0.4Mg (mass fraction, %) alloy powders with particle sizes of 15–53 μm and 30–75 μm were produced using electrode induction gas atomization (EIGA) and the plasma rotating electrode process (PREP), respectively. Bulk alloys were fabricated using LPBF, and the processing windows for both powders were compared to investigate the effects of powder morphology and particle size on the microstructural and mechanical properties. The results indicated that PREP powders, which exhibited better sphericity and larger particle size, had a broader and more stable LPBF processing window. This led to bulk samples with higher density and smaller grain sizes compared to those prepared with EIGA powders. Under optimal processing parameters (P = 50 W, V = 600 mm/s), both bulk sample types displayed similar tensile yield strength (210 MPa) and ultimate tensile strength (285 MPa). However, the compressive yield strength of the EIGA + LPBF samples ((288.2 ± 4.3) MPa) was slightly higher than that of the PREP + LPBF samples ((258.5 ± 3.5) MPa). By contrast, the PREP + LPBF samples demonstrated significantly greater tensile elongation (21.8% ± 2.3%) compared to the EIGA + LPBF samples (3.3% ± 0.7%). This enhanced ductility was primarily attributed to the more homogeneous thermal conductivity and strain distribution in PREP powders during the LPBF process. These findings offer valuable insights into raw material selection, microstructural control, and mechanical property optimization for LPBF-processed low-melting-point zinc-based alloys.