Abstract: An apparatus and method for forming essentially contaminant free metal powders of varying particle diameter by utilizing a separate gas percolation chamber for admitting a separate clean variable pressure percolating gas into a molten metal passing through a transfer tube, forming a metal froth which is sprayed into a reduced pressure collection chamber. The metal froth then disintegrates providing a finely divided powder which is cooled in the suspension state and collected. By utilizing a separate percolation chamber for independently pressurizing the metal froth, impurities are reduced and froth characteristics are controllably modifyable thereby providing essentially contaminant free metal powder of varying particle diameter. In addition, pressure equalization means are disclosed for overcoming pressure imbalances on start-up.