Processing magnetocaloric materials into magnetic refrigerant particles is an essential issue in developing high-performance magnetic refrigerators. Here, we succeed in stably producing magnetocaloric particles of the promising material HoAl2 by a newly devised method based on electrode induction melting gas atomization process. The particle size range is on the order of submillimeters, which is suitable for practical refrigeration systems. The resulting particles with less contamination have good morphological, magnetic, and magnetocaloric properties: (i) almost spherical shapes with few internal pores, (ii) a sharp ferromagnetic transition around 30 K, and (iii) a large magnetocaloric effect comparable to the bulk counterpart. These features suggest the HoAl2 gas-atomized particles have the potential of use as a magnetic refrigerant. The presented method can be applied not only to HoAl2 but also to other brittle magnetocaloric materials with high melting points, facilitating the production of various magnetic refrigerants needed to develop magnetic refrigerators for hydrogen liquefaction.
