Interesting. One observation I made during the airstone test of the blue stones is that the 4" and the 6" seemed to disrupt the water equally or at least as close to equal as I can discern with the naked eye. Perhaps the 6" moved a little more water. However, while taking pictures of the stones with my underwater camera, the 6" seem to be putting off more actual "air stone" sized bubbles. It was almost as if the high pressure and smaller stone combo caused many more bigger bubbles to form. As if the pump was simply over sized for the smaller stone.
You make an excellent point however about DO rates and free oxygen amounts. It seems that for the ebb/flow crowd or those mixing large batches of soil water, a cheap pump and cheap stone is more than enough to reach full DO rates. There is absolutely no reason to be spending money on expensive diffusers or multiple stones in a rez.
For those that are growing with plants immersed in water, it is pretty obvious that free air levels are key as this is what plants need and any stone is going to easily surpass maximum DO pretty quickly.
To that end, I was thinking about the diffuser -vs- regular air stones. The diffuser puts out lots of bubbles, but becuase the pore size is so small, it clearly passes less air through it. So the discussion then turns to which approach lends itself to more oxygen/root interface time or...which approach achieves the most oxygen surface area-- smaller bubbles, but less of them or bigger bubbles. If you took the same quantity of air and made bubbles out of them then the smaller bubbles would have more surface area collectively. However, that is not the case in the diffuser-regular stone decision as the diffuser is clearly allowing much less air to pass through it based on naked eye observations.
I may be biased towards the regular stones because the diffusers are sooo expensive. But I feel that all things being equal, the 6" blue stone or 2" round is more applicable to DWC simply because of thee ease at which it allows air to pass through it. As for one or two stones per DWC bucket, I'm still on the fence. There is the advantage of having two stones in that if one becomes clogged you have a back up so to speak. The other side of the equation is that two stones, when reaching the end of a growth cycle and the buckets are absolutely full of roots, would more evenly distribute the bubbles through the root zone.
Any thoughts?