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Stress Levels Cause Spring Failures

Stresses in materials are one source of failure for springs. Reducing stresses is always optimal in designs where possible. Some ways to reduce stress (assuming everything else is held constant in the design) include:

  • Use a thicker material or larger wire diameter
  • Use a larger spring (larger outer diameter)
  • Increase the pre-load of the spring (cyclical)
  • Decrease the maximum deflection (cyclical)
  • Reduce the amount of deflection in the application (Static)

Additionally the life of a spring can be extended with the same conditions/parameters with the following:

  • Changing the material or alloy
  • Special Heat Treatment Processes
  • Advanced surface finishing processes"
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