High-Throughput Particle Size Analysis of Battery Powders

Powder Uniformity Drives Performance

Battery-grade powders must meet demanding criteria not just in their chemistry, but also in size and shape. Inconsistent particle dimensions lead to irregularities in the electrode layer, which can cascade into poor cycle life, reduced capacity, and increased resistance.

Conventional SEM analysis can capture these differences, but it's often too slow, too subjective, or too limited in throughput. A more effective approach combines automated acquisition, nano-resolution imaging, and software-based size extraction, enabling consistent, high-throughput insights that support quality control and materials development. 

Automated Multiscale Imaging of Cathode Powder

The sample consisted of a Ni-based lithium-ion battery powder, representative of current-generation cathode materials. Three imaging scales were selected: 

Imaging was performed using a Tescan CLARA UHR SEM operated at 1 keV and low beam current. Using Essence™ Image Snapper, the system automatically acquired and optimized each image based on focus, contrast, and scale without operator input.

For size and morphology analysis, image stacks were processed using MIPAR, which extracted diameter distributions and particle shape metrics from binarized image data

Structural Domains and Phase Interfaces

Analysis revealed particle diameters ranging from 1.2 µm to 10.9 µm, with an average of 4.2 µm ± 1.2 µm. This degree of variability may influence flow characteristics during slurry mixing and affect how the electrode responds to calendaring.

High-magnification images showed clusters of smaller primary particles fused at grain boundaries, creating increased surface area, but also potential hotspots for degradation. Because the data was acquired at multiple magnifications, users could correlate global size trends with local texture effects.

This approach demonstrates how SEM-based surface analysis can deliver not just snapshots, but also insights into the links between particle design and electrochemical performance.