Choosing the Best Materials for Springs

Springs are everywhere. They are used in a variety of industries, from engineering and automotive to aerospace and retail, and the different types of springs that can be manufactured are almost as diverse as their uses – the same is true of the materials that springs are made of.

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Both the type of spring and the materials chosen will depend on the project you are working on and the applications of the product; no matter what you’re working on, it’s important to choose the material that offers the properties your project demands.

How do you decide which spring materials are right for your project? Below, we’re taking a look at different metals and their properties, as well as which applications they are best suited for.

What Determines the Best Material for a Spring?

As spring manufacturers, we’re aware of just how complex spring design and spring manufacturing are; before creating your spring, we need to know precisely what it will be used for, since this will help us to create the product to your exact specifications. This means we need to be aware of factors that may impact how the springs will perform, such as temperature and corrosion.

For instance, if the spring will need to perform optimally even at incredibly high temperatures, then this will help to determine the materials we’ll choose – Inconel alloys, which have a chromium-nickel base, are great for extreme environments, since it still retains its strength even when temperatures exceed 800oC. If you work in the oil and gas industry and require springs that can withstand corrosion from saltwater, for example, then stainless steel can be a fantastic choice, as this material won’t rust or weaken even in environments brimming with moisture.

The lifespan of the spring will also play a key role. Springs that are expected to be used thousands or millions of times over its life cycle needs to be able to withstand normal wear and tear. For instance, if a spring is part of an engine in a car, then it will be in use fairly often, which means it needs to be hard-wearing and durable.

Having the right spring material, therefore, is crucial to the manufacture of a product that will meet the demanding requirements of your project and of the industry, and that will stand the test of time.

So, which metals are commonly used in springs and why?

Different Metals for Different Springs

Stainless Steel

Commonly used for springs, this material is ideal for settings where higher corrosion or heat resistance is a necessity. This steel alloy has a minimum of 10.5% chromium content and a maximum of 1.2% carbon content. Stainless steel comes in several different grades, each with its own properties, as well as types: austenitic, martensitic and precipitation hardening.

Austenitic stainless steels are hardened by cold work and are useful for applications where resistance to corrosion is required; martensitic stainless steels also have good resistance to corrosion and are strongly magnetic, although they have poor electrical conductivity; and precipitation hardening stainless steels have high tensile strength and great resistance to fatigue, though they can crack due to stress.

This is a very popular and versatile alloy for springs and used in a variety of markets and sectors, including architecture, art, aerospace, chemical processing, food and transportation.

High Carbon Steels

This is also an extremely popular alloy used in the manufacture of springs. Carbon steels have a carbon content of up to 2.1%; the higher this percentage, the stronger the alloy will be. The properties of this material make it sought-after for springs, as it can offer great hardness levels and resistance to wear and tear. Hard drawn wires for low-stress applications come at a low cost, while higher tensile materials are best suited for high-stress applications and are more expensive.

High carbon steels are less ductile and more brittle than metals like steel, which means they won’t be suitable for environments where flexibility is a concern.

Nickel Alloys

Nickel is a versatile material that will alloy with many different metals, making it perfect for a range of environments where resistance to corrosion and high temperatures is a requirement. Nickel alloys also tend to offer a high level of strength and durability and remain reliable even in the most demanding of environments, like chemical plants or oil rigs. Nickel-based alloys are also commonly found in places where below-zero temperature applications are needed, and their nonmagnetic properties allow them to be used in indicating instruments and gyroscopes.

Cobalt-nickel alloys are often chosen when stainless steel is not enough. These alloys have high strength, are durable, have a great degree of ductility and outstanding resistance to corrosion and wear and tear.

The aim of this guide is to provide a comprehensive overview of different types of compression springs and their common applications. We will explore popular styles and sizes available from SpringXpert Ltd and offer insights into which springs to purchase for a variety of everyday uses. Additionally, we will delve into the mechanics of these springs and explain how to accurately measure them, making it easier to select the ideal coil springs for specific tasks.

Understanding Compression Springs

Compression springs, often referred to as coil springs, represent a classic form of spring. When compressed under a load, they generate a resisting (push back) force, endeavouring to return to their natural, uncompressed height or length. They are highly versatile and find application in various situations that necessitate a pushing force to counter opposing pressure. Consequently, they are present in a wide range of applications, from everyday items like ballpoint pens and bed springs to precision tools, vehicles, electronic devices, push-button switches, medical equipment, and heavy-duty industrial machinery.

In addition to providing an immediate pushback force, compression springs held under compression offer an efficient and economical method of storing significant potential energy. This proves invaluable in a multitude of products and scenarios. Most compression springs are crafted from open-coiled steel wire, providing a vast range of sizes, stiffness (spring rate), and cross-sectional designs and shapes. This includes specialised options like conical, concave, garter, barrel, and hourglass springs. In fact, there are few limitations to how large or small a coil spring can be manufactured. Tiny versions are often found in handheld electronic devices like mobile phones, keyboards, and switches, while products built for automotive or industrial use can be much larger and heavier.

How Compression Springs Work

Compression springs function by resisting and pushing back against any downward or inward force attempting to compress and hold them. They consistently push back, always seeking to return to their natural open or slightly extended state when not under pressure. Another way to describe their function is by comparing them to different types of springs, which are defined by the way they should be loaded.

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• A tension spring is designed to generate a pulling force. It is installed and held under tension while fully extended and will immediately try to return to a fully contracted state when released, effectively acting as the opposite of a coil spring.
• A torsion spring is held in twisted rotation around its central axis, wanting to snap back when pressure is released (or applied, in the case of an extorsion spring). Everyday examples of torsion/extorsion springs in action include clothes pegs, chair adjustment controls, workshop clamps, and various types of hinges.

The amount of force a compression spring can resist—its overall strength, stiffness, or spring rate—depends on various metrics and specifications, including its physical design, material strength, and manufacturing methods. However, generally, adjusting the ratio of wire diameter to overall spring diameter is the most effective way to make a compression spring stronger or weaker. Thicker wire or a narrower coil will increase the spring rate, while thinner wire or a larger diameter coil will result in a weaker spring force.

How to Measure Spring Length Accurately?

Measuring a spring accurately is essential in determining the precise size needed to create the required type of resistance force in a specific application. Multiple dimensions need to be considered, including length, wire diameter, outside diameter, and total number of coils. When measuring the length of a compression or coil spring, it should be done from end to end while in a coiled but uncompressed state, known as its free length. Placing the calliper at either end of the coiled spring while it rests loosely on a flat surface in its natural state (under no compressive force whatsoever) and measuring accurately is the recommended method.

Do springs wear out from compression?

Springs are commonly used in various applications, from car suspensions to mattress coils. One question that often arises is whether springs wear out from compression. The answer is not a simple yes or no.

When a spring is compressed, it experiences stress and strain due to the force being applied to it. Over time, this can cause fatigue and eventually lead to failure. However, the rate at which a spring wears out from compression depends on several factors.

The quality of the spring itself plays a significant role. A well-manufactured spring made from high-quality materials will have better durability and resistance to wear than a lower-quality one.

The amount of compression and frequency of use also affect how quickly a spring wears out. If a spring is constantly compressed and released with heavy loads, it will experience more wear compared to one that undergoes occasional compressions.

Proper maintenance and regular inspections can help identify signs of wear in springs before they fail completely. By replacing worn-out springs promptly, you can ensure optimal performance and prevent any potential safety hazards.

In conclusion,

while springs may indeed wear out from compression over time, various factors such as quality, compression amount and maintenance practices all contribute to determine how long they last. By understanding these factors and taking appropriate measures, you can maximsze the lifespan of your metal springs.

What is the lifespan of a spring?

What is the lifespan of a spring? This is a common question that arises when considering the durability and longevity of compression springs. While it's difficult to give an exact answer as various factors can affect the lifespan, there are some general guidelines to consider. The quality of the spring itself plays a significant role in determining its lifespan. A well-made spring from a reputable manufacturer will typically last longer than one made with inferior materials or craftsmanship. Additionally, proper maintenance and regular inspections can help extend its life.

How often the spring is used and under what conditions also impact its lifespan. Springs that undergo frequent heavy loads or extreme temperatures may wear out more quickly compared to those experiencing lighter usage.

Environmental factors such as humidity or exposure to corrosive substances can also contribute to degradation of failure over time.

While it's challenging to provide an exact timeframe for how long a spring will last, taking into account these considerations can help ensure optimal performance and maximize its lifespan.

Types of Compression Springs

Here at SpringXpert, we offer a multitude of compression spring types, styles, and sizes. Compression spring manufacturers offer high-quality products in various diameters, lengths, and materials to cater to every industry and application. While the majority are made from open-coil steel wire (often stainless steel or high carbon steels), compression springs made of nickel-alloy, chromium silicon, and beryllium copper are also widely available.

What is another name for a compression spring?

Compression springs are versatile mechanical devices that are widely used in various industries. They are known for their ability to store and release energy, making them essential components in many applications. But did you know that compression springs also go by another name? Yes, they are sometimes called coil springs.

Coil springs, or compression springs as they are commonly referred to, work by absorbing force when compressed and then releasing it when the pressure is removed. This makes them ideal for applications where there is a need for resilience and shock absorption. The tightly wound coils of these springs provide resistance against compression forces, allowing them to withstand heavy loads.

While compression springs may be similar to other types of metal springs like extension and torsion springs in terms of their function, each type has its own unique characteristics and uses. Compression springs specifically excel in applications where linear force is required. So remember, if you ever come across the term "coil spring" while researching or discussing metal spring options, know that it's simply another name for the popular and versatile compression spring!

Regardless of their size and stiffness, the standard design of a compression spring typically involves a helical wire coil. This can be compacted and held under varying amounts of pressure, but in its natural state, any true coil spring will immediately return to its fully extended form. Conical compression springs are also available, although they are less common.

Different types and formats of compression springs include:

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