Fatigue behaviour of helical compression springs at a very high number of cycles – Investigation of various influences

Long-term fatigue tests on shot peened helical compression springs were conducted by means of a special spring fatigue testing machine at 40 Hz. Test springs were made of three different spring materials – oil hardened and tempered SiCr- and SiCrV-alloyed valve spring steel and stainless steel. With a special test strategy in a test run, up to 500 springs with a wire diameter of d = 3.0 mm or 900 springs with d = 1.6 mm were tested simultaneously at different stress levels. Based on fatigue investigations of springs with d = 3.0 mm up to a number of cycles N = 109 an analysis was done after the test was continued to N = 1.5 × 109 and their results were compared. The influence of different shot peening conditions were investigated in springs with d = 1.6 mm. Fractured test springs were examined under optical microscope, scanning electron microscope (SEM) and by means of metallographic microsections in order to analyse the fracture behaviour and the failure mechanisms. The paper includes a comparison of the results of the different spring sizes, materials, number of cycles and shot peening conditions and outlines further investigations in the VHCF-region.