MnAl is a promising low-cost rare-earth-free permanent magnet material, with the metastable ferromagnetic τ-phase being key to its magnetic performance. This is due to its high magnetic anisotropy, good saturation magnetization, and a reasonable Curie temperature coupled with the affordable raw materials. However, the practical application of MnAl alloy was reported to be greatly hindered by the difficulty in obtaining the pure τ-phase, which was due to the easy decomposition of metastable τ-phase into the stable nonmagnetic γ2 (Al8Mn5) and β (Mn) phases. Hence, this study conducts the metallurgical characterization of as-cast ingot and atomized powder of Mn55Al45 alloy produced using Amazemet rePowder system. Main objective is to find out in which form is the τ-phase easily obtained. The alloy was melted under controlled argon atmosphere to limit contamination. X-ray diffractometer (XRD) and scanning electron microscopy (SEM) were used to track phase and microstructural changes, respectively. Both SEM and XRD analysis confirmed the presents of τ and β phases in the as-cast (AC) ingot, whereas fine powder exhibited τ, β and γ 2 and Al11Mn4 phases. Furthermore, β, ε, δ, and τ phases as well as Al phase were detected by XRD technique in the coarse powder. Findings from this study will serve as a basis process for developing high performance permanent magnets that are free of rare earth-elements.