Introduction

Springs are critical components in countless mechanical systems, and when they fail or perform unexpectedly, they can cause significant problems throughout an assembly. This comprehensive troubleshooting guide addresses common spring failure modes, performance issues, and solutions to help engineers and maintenance professionals quickly identify and resolve spring-related problems.

Compression Spring Issues

Problem: Spring Takes a Permanent Set (Loss of Free Length)

Symptoms:

• Spring becomes shorter than original specifications
• Decreased force output
• System no longer reaches required positions

Possible Causes:

• Spring compressed beyond yield point
• Operating temperature exceeds material limits
• Material creep under sustained load
• Improper heat treatment during manufacturing

Solutions:

• Replace with higher tensile strength material
• Select material appropriate for operating temperature
• Consider variable pitch design to distribute stress more evenly
• Redesign for lower operating stress (larger wire diameter or more coils)
• Implement stress-relieving process during manufacturing

Problem: Spring Buckling

Symptoms:

• Spring bends sideways during compression
• Inconsistent force across compression cycle
• Increased wear on surrounding components

Possible Causes:

• Length-to-diameter ratio too high
• Improper alignment or guiding
• Uneven end surfaces
• Excessive compression

Solutions:

• Use a guide rod or sleeve to prevent lateral movement
• Redesign spring with larger diameter or shorter free length
• Ensure proper end conditions (ground ends for better stability)
• Consider using multiple smaller springs in parallel

Note: Additional spring failure issues and solutions follow the same structure and should be implemented in similar sections for completeness.

Need Additional Help?

If you're experiencing spring issues not covered in this guide or need assistance with a specific application challenge, our engineering team is available for consultation. Contact a Lee Spring Engineer or call us 888-777-464 to speak with a spring design specialist.