Metal Springs

Springs are toughened metal coils that store and release energy, helping objects to return to a particular position. They stretch when a force is applied to them and returns to their original shape when released. Springs are elastic, and their change in shape depends on the amount of force applied to them. A large amount of force on a spring sometimes deforms it, so it never returns to its original shape. Springs fail through metal fatigue as continuous stretching makes the internal alteration. Spring structures get microcracks in them and eventually break down after repeated use.

Materials Used in Metal Springs

The composition of metal springs depends on their application, the amount of stress or stretch it has to bear, the heat and temperature it is to cope with, the corrosion to withstand, and the shape of the spring during its manufacture. Generally, all springs are made of steel alloys as it is the most common material.

Other alloys include high carbon, oil tempered low carbon, chrome silicon, chrome vanadium, stainless steel, beryllium copper, phosphor bronze, and titanium. Rubber or urethane material is used for non-coil springs. However, for coiled springs, ceramic material is used to make them work in high-temperature environments. Testing is also done on one-directional glass fiber composite material for using it in spring manufacturing.

Manufacturing Process of Metal Springs

The following steps can describe the manufacturing process of metal springs:

1. Coiling

   The first step is wire coiling, which can be cold winding or hot winding. Cold winding is done at room temperature, while hot winding needs heat treatment for the coiling and is then dipped into oil for rapid cooling.

2. Hardening

   Wires are stressed during the coiling process, but this can be relieved by heating them in an oven at a high temperature for a specific amount of time.

3. Finishing

   Finishing is the last step of the manufacturing process. Shot peening is done to cut out metal fatigue, while coating is done to prevent the spring from corrosion.

Types of Metal Springs

Metal springs are available in a large variety, and their selection depends solely on their application. The most common types are:

Compression Springs

• A compression spring is an open-coiled helical spring that offers resistance to compressive force.
• The coiling is of equal diameter and can be made in any shape.
• It can store energy or resist force depending on the application in which it is used.

Torsion Springs

• Torsion springs exert torque or rotary force.
• These springs are attached to the component, and when it rotates, the spring pushes them back to their original space.
• These springs can work clockwise and anticlockwise depending on their application.

Extension Springs

• Extension springs can store energy as well as offer resistance upon expansion.
• These springs are attached to components on both sides.
• They offer resistance upon expansion and return to their original position when released.

Constant Force Springs

• It is the most basic and versatile spring of all.
• It is a pre-stressed flat strip of spring placed around its own radius.
• It works nearly the same as the extension spring.
• A constant torque is achieved if the spring is attached to another spool.

Belleville Springs

• These are slightly tapered disc-like springs, also known as washers.
• These are used for pre-tensioning purposes and are available in various materials.

Drawbar Springs

• Drawbar springs are ideal to use in overload situations.
• These offer a built-in safety feature to carry on the static load.
• The load is applied on the ends of steel bars and then passed to the center of the spring, offering compression.

Volute Springs

• It is a cone-shaped compression spring.
• These are compressed to a very short length compared to the conventional helical springs.
• They are mainly used in garden secateurs.

Garter Springs

• It is a coiled steel spring that’s both ends are connected to give it a circular shape.
• These are found in oil seals, shaft seals, and electrical connectors.
• The material used for its manufacture is either carbon steel or stainless steel wire.

Flat Springs

• Flat springs are small, stamped metal components that work as a spring.
• These are flat springs that control deflection in small and restricted spaces.
• These springs store and release energy and are made from high carbon steel, copper alloys, or titanium alloys, according to the application.

Air Springs

• Air springs are air pressurized bellows or bladder-type devices.
• These are used in shock absorption and vibration isolation.
• These are also known as air cushions used in lifting and compression.

Applications of Metal Springs

Metal springs are used in the automobile industry for clutches, brakes, and shock absorbers. These are also used in gardening tools, doors, windows, spring balance, watches, toys, and many other household items.