The size and shape of individual particles are essential characteristics to control their behavior during spraying. Thanks to recently available technology in powder image analysis, this paper investigates the correlation between the geometric properties of several thousands of particles and their flowability (Hall flowmeter) and apparent density (Scott volumeter). Four different chromium carbide Cr 3 C 2 -NiCr 75/25 powders used for HVOF wear / oxidation resistant coatings are studied. The coating quality obtained for each powder by the HVOF spraying process is further investigated using metallographic image analysis.