Influence of particle shape on size distribution measurements by 3D and 2D image analyses and laser diffraction

This paper highlights the fact that particle size distribution (PSD) is not unique for the same product, and is dependent on the chosen measurement technique, especially for asymmetric shapes. Laser diffraction and 2D image analysis are commonly used PSD measurement techniques. However, the resultsmay not be representative of the true physical dimensions of the particles.
The influence of particle shape on PSD results obtained from 2D/3D image analysis and laser diffraction was investigated. Two metallic powders presenting extreme shape properties (round and elongated particles) were analyzed, as well as a blend of the two pure products. 2D image analysis and laser diffraction results were compared to 3D image analysis (measuring the true particle size). This paper compares the PSD results obtained from the three methods.
Some commonly used size parameters in image analysis software did not give meaningful results in regard of the true physical dimensions of the particles. The existence of the two populations (products with extremely different shape and size characteristics) could not be identified with such size parameters, and laser diffraction also performed poorly. The PSD obtained from more precise size parameters (image analysis) better corresponded
to the true dimensions of the particles.
This study highlights the strengths and weaknesses of particle size analysis techniques when studying products presenting diverse particle shapes, and points out that caution is required in the choice of the size parameters, and in the interpretation of PSD results.