Common Spring Failures & How to Prevent Them

Springs are deceptively simple components, yet their failure can lead to significant production delays, costly rework, and even damaged reputations. For OEMs, Tier 1 suppliers, and sourcing heads in industries like automotive, electricals, and appliances, ensuring spring reliability is not just about performance—it’s about business continuity.

Let’s break down the most common types of spring failures, why they happen, and how you can avoid them.

1️⃣ Fatigue Failure – The Silent Culprit

What it is: Springs are exposed to repeated cycles of compression, extension, or torsion. Over time, this repetitive loading can cause cracks that eventually lead to complete failure.

Why it happens:

• Poor material quality
• Incorrect spring design
• Lack of fatigue testing

How to prevent it:

• Choose high-grade raw materials certified for fatigue resistance
• Work with suppliers who provide design optimization support
• Insist on springs tested for fatigue cycles relevant to your application
   

2️⃣ Overloading – Asking Too Much of a Small Part

What it is: When a spring is subjected to forces beyond its design limits, it can permanently deform or break.

Why it happens:

• Using the wrong type or size of spring for the job
• Unanticipated loads in the application

How to prevent it:

• Ensure precise load calculations during the design stage
• Consult with experienced spring manufacturers for application-specific recommendations
   

3️⃣ Corrosion – The Hidden Enemy

What it is: Springs exposed to moisture, chemicals, or extreme environments can corrode, leading to weakened performance and eventual failure.

Why it happens:

• Inadequate surface treatment
• Wrong material choice for corrosive environments

How to prevent it:

• Opt for corrosion-resistant materials or coatings (e.g., stainless steel, zinc plating, powder coating)
• Discuss environmental conditions with your spring supplier to select the right finish
   

4️⃣ Dimensional Inaccuracies – Small Errors, Big Consequences

What it is: Variations in wire thickness, coil spacing, or overall dimensions can cause mechanical issues, improper fits, or inconsistent performance.

Why it happens:

• Poor manufacturing precision
• Lack of in-process quality checks

How to prevent it:

• Partner with precision spring manufacturers who use CNC coiling, in-process inspections, and dimensional certifications
• Request quality documentation with each batch
   

5️⃣ Improper Heat Treatment – Undermining Strength

What it is: Heat treatment hardens the metal and improves spring strength. Without proper heat treatment, springs may deform under stress.

Why it happens:

• Inexperienced suppliers cutting corners
• Inadequate process control

How to prevent it:

• Choose an ISO 9001:2015 certified spring supplier with stringent process control
• Insist on proper certifications for heat-treated components
  
   

Why Choose Ranoson?

At Ranoson, we’ve been partnering with leading OEMs and Tier 1 suppliers to deliver springs that last. From selecting the right materials to rigorous testing protocols, we build reliability into every product we manufacture.

As a custom spring an wire form manufacturer, we offer:

• Expertise in springs and wire forms for automotive, electricals, industrial equipment, and more
• Just-in-time deliveries to minimize your inventory burden
• In-depth technical support to solve your application challenges
   

Let’s Build Reliability Into Your Supply Chain

Don’t let common spring failures derail your operations. Partner with experts who understand your challenges and deliver solutions you can rely on.

Let us help you accelerate your growth with springs that last.
📧 sales@ranoson.co.in | 📞 +91 7895010088