Material Considerations For Compression Spring Applications
A compression spring is any spring that offers resistance to compressive loading and reduces in size on application of an external load
. These types of springs are generally used in applications that require a resistance to compressive force. Typically, compression springs are open coiled, helical springs, but some other types of compressions springs are volute springs and Belleville springs.Application of Compression Springs:
Compression springs are used in a wide range of applications such as automotive, electronics, medical, durable/commercial goods, and industrial. Though the springs are produced in various sizes and shapes to suit each type of application, a number of factors are considered while selecting or designing a compressive spring. The chief factor considered is the spring material. While choosing a spring for a specific application, the helix direction, ground ends, solid height, spring rate, total number of coils in the spring, free length, and wire diameter are also taken into account.
Materials Used to Construct Compression Springs:
Compression springs are produced in a wide range of materials such as chrome-silicon, high carbon steel wire, stainless steel, alloy steel or music wire, brass, zinc, and nickel base alloy wire. These materials are chosen based on the requirements of the application such as tensile strength, elasticity, and torsion. Another factor that has a significant impact on spring material selection is the temperature range within which the material can operate. Properties of some of the popular materials used for manufacturing springs are discussed below:
1. Music Wire
Music wire is an inexpensive, high-carbon steel alloy that offers uniform tensile strength that ranges from 229 to 300 (psi x 103), and compared to other spring materials, has a high tensile strength to resist higher stresses. Its ability to withstand high stresses under recurrent loading conditions makes it ideal for cyclic applications. In addition, springs made of music wire are suitable for applications demanding high strength, medium price, and uniformly high quality. Springs made from music wire are suitable for applications having a maximum operating temperature of up to 250 degrees F (121 deg C). This material also has a modulus of elasticity and modulus in torsion of about 30 (psi x 106) and 11.5 (psi x 106) respectively.
2. Stainless Steel
A number of compression springs are constructed using stainless steel, for use in specialty applications that require good corrosion resistance. Their resistance to corrosion makes these springs ideal for use in the food processing industry and other applications that require prolonged exposure to the water or steam. Springs made from austenitic stainless steel also offer good resistance to acids. The modulus of elasticity and modulus in torsion of this material are 28 (psi x 106) and 10 (psi x 106) respectively. Furthermore, the tensile strength of stainless steel ranges from 125 to 320 (psi x 103).
3. Chrome Vanadium
Chrome vanadium is another typical material used for fabricating compression springs, particularly for moderately elevated temperature applications. As chrome vanadium does not change dimensionally when exposed to heat, springs made from this material can operate in temperatures up to 425 degrees F (220 deg C). In addition, compared to some high carbon steel materials, chrome vanadium has improved stress, fatigue, and long endurance life conditions. This material has modulus of elasticity of 30 (psi x 106) and a modulus in torsion of 11 (psi x 106). Furthermore, the tensile strength of the material ranges from 190-300 (psi x 103). Chrome vanadium is also suitable for applications having impact and shock loading conditions.
4. Chrome-Silicon Wire
Compression springs produced using chrome-silicon wire typically have prolonged service lives and shock loading resistance. Similar to chrome vanadium, this spring material can also withstand moderately elevated temperatures, as it does not change dimensionally when exposed to elevated temperatures. Chrome silicon wire can withstand a maximum temperature of up to 280 degrees F (250 deg C).
5. Inconel
Springs made from Inconel are typically used for high-temperature applications. Inconel springs can operate in applications that warrant temperatures up to 1100 degrees F. Furthermore, this material also offers good corrosion resistance at high temperatures.
6. Nickel Based Alloys
Apart from ferrous-based spring materials, nickel-based spring materials are also commonly used. This material can withstand wide temperature fluctuations and is corrosion resistant as well. Nickel-based alloys are typically used in precise instruments due to their non-magnetic characteristics. Furthermore, springs made from this material offer high resistance to electricity, ruling out their use as electrical conductors.
7. Other Materials
Compression springs are also manufactured from a wide range of other material, including beryllium copper, Monel, phosphor bronze, and titanium. While the good electrical conductivity of phosphor bronze makes it ideal for electrical components, titanium springs are commonly found in aerospace applications, as they are light in weight. Springs made from brass are often used in electrical components due to its good electrical properties.
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