Close-coupled gas atomization (CC-GA) has great potential for enhanced industrial-scale production of pre-alloyed powder with top quality for additive manufacturing (AM). However, there is a need for powder “satellite” reduction to promote sphericity and flowability, particularly in coarser powders with a reduced cooling rate that are prone to “welded” attachment of finer powders in the turbulent environment of an atomizer. Coarser GA powders also may have excess interior gas porosity that is not eliminated during melting and cannot be healed by post-build hot isostatic pressing. Various strategies have been developed to address these powder quality issues including macro-flow modeling and experimental testing/observations of atomizer spray chamber modifications and droplet breakup modeling and experimental atomization gas flow energy adjustments and resulting porosity analysis. Results are reported to show progress in gas atomization process research to mitigate these issues for Ni and Ni-based alloy powders.