RECENT FINDINGS TO THE FATIGUE PROPERTIES OF HELICAL

SPRINGS

Bruno KAISER and Christina BERGER

Institute for Materials Technology and State Materials Testing Institute Darmstadt, Darmstadt University of
Technology, Grafenstrae 2, 64283 Darmstadt, Germany
TEL:+ 49-6151-16-2840 FAX:+49-6151-16-6118 e-mail:kaiser@mpa-ifw.tu-darmstadt.de

The paper firstly presents results of fatigue tests on a variety of helical springs up to a number of 107 cycles.
These results were obtained in a research project which extensively investigated the fatigue properties of helical
springs with five different wire diameters (1, 2, 3, 5 and 8 mm) up to 107 cycles. The test springs for this project
were made out of six different spring materials, two patented cold drawn unalloed spring steel wires, two oil-
hardened and tempered spring steel wires and two stainless spring steel wires. The results of these fatigue tests
with different mean stresses were statistically evaluated, presented as fatigue strength diagrams according to
Goodman for a test limit of 107 cycles and compared to existing values of standards.
Subsequent long-term fatigue tests on selected springs were carried out up to a maximum of 1,5 x 109 cycles. An
increase of the stress cycles from 107 to 1,5 x 109 cycles leads to a remarkable reduction of the long-term
fatigue range of shot peened springs manufactured from oil-hardened and tempered spring steel wire.

Keywords : helical springs, fatigue range, Goodman-diagrams, wire diameters, very high cycle fatigue,
spring materials, shot peened

1. INTRODUCTION: SOME ASPECTS OF THE springs to the necessary level.

FATIGUE BEHAVIOUR OF COLD FORMED
HELICAL SPRINGS
Springs are usually estimated as simple and self-
evident components, because they often appear in every
day life and also seem to be relatively cheap.1)
Technical Springs, however, belong to the components
with the highest cyclic and superposed static load.
Nevertheless they have to satisfy - among others - the
needs of lightweight constructions. Recent requirements
for a great number of technical springs, used in
constructions for engines and vehicles, can only be
fulfilled, if high strength materials with special
properties are carefully manufactured to well designed
springs and furthermore additional treatments are
applied. Especially shot peening or stress peening
combined with presetting in the case of pulsating
stressed springs are very important and efficient
treatments to improve the fatigue properties of technical
Helical compression springs are used in numerous
applications with high stress amplitudes under
simultaneous high mean stress, for example in valve
drives of combustion engines or as springs in fuel
injection systems. A spring fatigue failure often leads to
significant trouble and must be avoided with high
reliability. Furthermore, new requirements at very high
load cycles are important issues in investigations.2)
The development of metal springs in the past years
was aimed by improving technological functionality
with as little operating weight as possible.3) Owing to
the requirements of light-weight construction, the
mounting spaces for such springs become increasingly
smaller so that helical compression springs are
subjected to constantly rising specific stresses. A whole
variety of expensive measures were developed in order
to guarantee the required properties, such as, amongst

97
 others:
Optimisation of the cast surface for the
avoidance of spring fractures,4) thermo-
mechanical treatment for spring steels for
suspension springs,5-8) induction tempering of
high tensile valve spring wires,9, 10)
Use of special spring steel wires (for example Si-
Cr- or Si-Cr-V-alloyed oil hardened and
tempered spring steel wires) pursuant to DIN EN
10270,11) partly in so-called super-clean quality
from peeled or ground raw material,12) crack-
tested, or alternatively, from corrosion resistant
spring steel wires
Careful manufacturing of the springs with
special respect to their surface zone, hot
presetting, shot peening (if necessary, at
increased temperatures, under prestress or in
combination with nitriding).13-16) The require-
ments made on the surface quality are extremely
high. According to,1) the surface quality in fact
plays a more important role for the operational
durability of the spring than the material
properties.
2. DETERMINATION OF GOODMAN DIAGRAMS
FOR HIGHLY SRESSED HELICAL COMPRESSION
SPRINGS
2.1 Reasons and motivations for the investigation
In 2001 the new European Standard DIN EN 10270,
Steel wire for mechanical springs was edited,11)
containing the three parts
1: Patented cold drawn unalloyed spring steel wire
2: Oil hardened and tempered spring steel wire and
3: Stainless spring steel wire.
This standard introduced new names characterizing
the different spring steel wire grades. The tables 1 and 2
show the classification of oil hardened and tempered
spring steel wires according to EN 10270-2 and the
patented cold drawn unalloyed spring wires according
to EN 10270-1 as a function of tensile strength and kind
of loading.
Table 1. Classification of oil hardened and tempered
spring wires according to EN 10270-2 as a function of
tensile strength and kind of loading

tensile Static Medium High

strength fatigue fatigue
low FD TDC VDC
medium FDCrV TDCrV VDCrV
high FDSiCr TDSiCr VDSiCr
range of 0,5 to 17 0,5 to 0,5 to
diameter mm 10 mm 10 mm

Table 2. Classification of patented cold drawn

unalloyed spring steel wires according to EN 10270-1
as a function of tensile strength and kind of loading

tensile Static Dynamic

Fig. 1. Survey of all spring variants tested, from left to strength (cyclic)
right: made from stainless steel wires X10CrNi18-8 and low SL -----
X7CrNiAl17-7, patented cold drawn unalloyed steel medium SM DM
high SH DH
wires DM and DH, oil hardened and tempered steel
wires TDSiCr and VDSiCr; wire diameters 1, 2, 3, 5
For a fatigue-safe design of high stressed helical
and 8 mm
compression springs suitable materials values are
necessary, if possible in terms of complete fatigue
strength diagrams (Goodman-diagrams). They show the
endurable maximum stress of a fatigue stressed spring

98
versus the minimum stress. The difference between the
maximum and the minim stress in the Goodman-
diagram is equivalent with the so called stroke stress
(= two times the amplitude stress). The stroke stress is
commonly calculated by using a correction factor k,17)
which is dependent on the curvature of the wire. The
curvature can be characterised by the quotient from the
mean spring diameter and the wire diameter, the so
called spring index.
Goodman-diagrams as a base for the design of helical
compression springs made from different spring wires
were a part of the former German standard DIN 2089
which was guilty from 1984 till 2001. With the revision
of that standard and its new edition as European
standard DIN EN 13906-1 Cylindrical helical springs
made from round wire and bar Calculation and design
Part 1: Compression springs the existing Goodman-
diagrams were taken over.18) Only the names of the
springs steel wire grades were changed according to the
already mentioned DIN EN ISO 10270 Steel wire for
mechanical springs.11)
These alterations in the basic standards gave rise for
the determination of new Goodman-diagrams by means
of a research project. Another reason was that the
available Goodman-diagrams in the standard DIN EN
13906-1 originate from 1984 and do no longer accord
to the recent state of spring technology.17)
The aim of this research work was to determine
statistically based results for the fatigue properties of
helical compression springs made of various spring
steel wire materials, which were to be tested in wire
diameters between 1 mm and 8 mm. As final results
Goodman-diagrams should be drawn for the different
spring variants.
2.2 Fatigue test program and procedure
Fig. 1 shows all variants of springs investigated in
that research project. The test program included springs
made from two stainless spring steel wires X10CrNi18-
8 (material No. 1.4310) and X7CrNiAl17-7 (material
No. 1.4568) with diameters of 1, 2, 3 and 5 mm. Two
grades of patented drawn spring steel wire (DH and
DM) were investigated in terms of springs with wire
diameters of 1, 2, 3, 5 and 8 mm (8 mm only in case of
DM). The steel wire named DH is designed for high
fatigue load, whereas DM is a similar material designed
for moderate fatigue load.
Two variants of springs made from oil hardened and
tempered spring steel wires with wire diameters of 1, 2,
3, 5 and 8 mm completed the test program. VDSiCr
defines a Silicon and Chromium alloyed (valve) spring
steel wire for highest fatigue requirements, TDSiCr an
equally alloyed spring steel wire for applications with
medium fatigue load.
Table 3 contains the values of the chemical
compositions (% by mass) of the investigated wire
grades according to DIN EN 10270-1, -2 and -3. Table
4 represents the tensile strengths of the wire variants
before manufacturing the test springs.
The spring index for the fatigue tested springs was w
= D/d = 6 in all cases. Some spring variants with a
spring index w = 4 shown in fig. 1 were only used for
relaxation investigation. Test springs made of DH, DM,
VDSiCr and TDSiCr were generally shot peened
(except some special series for reference purposes) and

Table 3. Chemical composition (% by mass) of the investigated wire grades according to EN 10270-1, -2 and -3;
*covers the whole range of wire diameters. For single diameters the C-content is limited distinctly narrower.

P Cu
Material C Si Mn S (max) Cr Ni Mo Al
(max) (max)
DM 0,45- 0,10- 0,50-
0,020 0,025 0,12 --- --- --- ---
DH 1.00* 0,30 1,20
TDSiCr 0,50- 1,20- 0,50- 0,1 0,50-
0,025 0,020 --- --- ---
VDSiCr 0,60 1,60 0,90 0,06 0,80
0,05- max. max. 16,00- 6,00-
X10CrNi18-8 0,045 0,015 --- 0,80 ---
0,15 2,00 2,00 19,00 9,50
max. max. 16,00- 6,50- 0,70-
X7CrNiAl17-7 0,09 0,040 0,015 --- ---
0,70 100 18,00 7,80 1,50

99
 Table 4. Tensile strengths of the investigated wire grades (actual values)

Material Tensile strength [MPa]

wire diameter 1 2 3 4 5
[mm]
DM 2127 2006 1740 1632 1512
DH 2363 2214 1968 1725 1753
TDSiCr 2190 2116 1938 1894 1776
VDSiCr 2134 2216 2016 1905 1799
X10CrNi18-8 2006 1793 1616 1484 -----
X7CrNiAl17-7 1902 1744 1453 1369 -----

pre-set, whereas the test springs made of stainless to 12 x 106 cycles (5 x 106 cycles in case of springs
spring steel wires were not shot peened (except two with 8 mm wire diameter).19)
special series with 1 mm wire diameter for reference
purposes), but pre-set, too.
Approximately 120 fatigue test runs were performed
with totally three spring testing machines. Two of them
are Bosch spring testing rockers, see Fig. 2, for
compression springs with wire diameters up to 5 mm.
The Bosch spring testing rocker (testing frequency 20
Hz) offers 8 levels of amplitude stress with up to 20
testing positions per level, dependent from the spring
size. The second testing device for the simultaneous
fatigue testing of 12 springs with a wire diameter of 8
mm is shown in Fig. 3 (testing frequency 3 Hz). Fig. 3. ASKON spring testing device for the fatigue
testing of 12 helical compression springs with a wire
diameter of 8 mm simultaneously

The tests were statistically evaluated according to the

8 7 6 5 4 3 2 1 arcsinp-method resulting in S-N-curves for fracture
probabilities of 10, 50 and 90 %. Normally the results
of three or four S-N-curves with different levels of
minimum stress were transferred into a Goodman-
diagram.

2.3 Special tests determining the permanent setting

Fig. 2. Bosch spring testing rocker for the fatigue
testing of 144 helical compression springs with a
wire diameter of 2 mm simultaneously
Altogether nearly 10.000 test springs were tested at
different levels of minimum stress up to a number of 10
(loss of length) of test springs during cyclic loading
It is important to mention that the standard DIN EN
13906 limits the allowable torsion stress range
(maximum stress resulting from minimum stress +
stroke stress, horizontal upper line in the Goodman-
diagram) to kO = 0,5 x Rm. Evaluating the S-N-tests and
elaborating Goodmandiagrams, however, it became

100
obvious, that the fatigue stroke strength especially of
shot peened helical springs made from oil hardened and
tempered valve spring steel wires range distinctly
above this limit. Therefore a limit of 0,5 x Rm. seemed
to be a too strong restriction in relation to the high
endurable amplitudes of the test springs.
This observation was the reason to check if this limit
could be increased to kO = 0,6 Rm for certain materials,
taking into account the amount of permanent setting, i.
e. the loss of test spring length. That reduce of the
effective pre-stress is only appearing significantly in
cases of very high starting values of the minimum stress
and was considered when calculating or drawing the
Goodman-diagrams.
In usual fatigue tests highly loaded springs will
fracture before the tests end (107 cycles) and will not
permit to measure the final spring lengths after the test.
Therefore additional (short term) fatigue tests with the
highest minimum stress and according amplitude
stresses applied were performed up to about 50.000
cycles. Until to this number of cycles almost no spring
fractures appear, but on the other hand this number of
cycles is supposed to be sufficient to lead to a steady
state of setting process due to cycling with constant
amplitudes.
Table 5. maximum stresses kO 0,1 mm , leading to an
amount of setting (loss of length) of about 0,1 mm
mate- kO 0,1mm [MPa] for wire diameter
rial 1 mm 2 mm 3 mm 5 mm
DM 1200 1200 1100 1000
DH 1300 1200 1150 1050
TD 1400 1400 1250 1200
VD 1500 1400 1300 1200
These tests made it possible to measure the loss of
length due to plastic deformations of the test springs
before the fatigue fracture appeared. The lengths of all
test springs were measured before and after the tests.
Table 5 shows, at which maximum stresses kO (MPa)
an amount of setting of 0,1 mm is to be observed.
The amount of permanent setting, drawn versus the
maximum stress (calculated by means of the correction
factor k) is shown as an exemplary diagram in figure 4.
The results of these tests point out, that the before
mentioned upper limit of allowable torsion stress may
be shifted at least to 0,6 x Rm for the materials VDSiCr,
TDSiCr and X7CrNiAl17-7 (1.4568).
Although there is a significant correlation between
the amount of setting and wire strength, especially for
larger plastic deformations, it is important to mention,
that starting point and amount of cyclic setting are
mainly influenced by the presetting process.
1800
1700
corrected maximum torsional stress
1600
1500
1400
[MPa]
1300
1200 1 mm
2 mm
1100
1000
3 mm
5 mm
900
800
0 0,5 1 1,5 2 2,5 3
amount of setting by cyclic loading [mm]
Fig. 4. Setting behaviour during cyclic testing of shot
peened helical compression springs from oil hardened
and tempered SiCr-alloyed spring steel wires with
diameters from 1 mm to 5 mm.
2.4 Test results: Goodman-diagrams
In order to enable a comparison, the Goodman-
diagrams representing the test results and the
Goodman-diagrams of the standard DIN EN 13906 are
presented correspondingly in the same diagrams. To
design these diagrams more clearly, only the Goodman-
diagram of the results for a failure probability of 10 %
are figured (without application of any safety factors).
Fig. 5 shows in its upper part Goodman-diagrams for
shot peened and pre-set helical compression springs of
oil hardened and tempered SiCr-alloyed spring steel
wire (VDSiCr) in 5 diameters from 1 to 8 mm. The
allowable stresses (upper horizontal lines) in these
diagrams are limited to 0,6 x tensile strength of the
corresponding wire as explained before. The ascending
lines of the diagrams represent the fatigue test results
for a failure probability of 10%. The lower part of Fig.
5 contains the Goodman-diagrams of the standard DIN
EN 13906 for shot peened and pre-set helical
compression springs of oil hardened and tempered
SiCr-alloyed spring steel wire VDSiCr in corresponding
101
 diameters. 5 mm (upper horizontal lines limited to 0,5 x tensile
strength) in comparison to DH-Goodman-diagrams of
1600
standard DIN EN 13906-1.
1400 fatigue test results for wire diameters d =
1600
2 mm
1 mm
1200 fatigue test results for wire diameters d =
3 mm 1400
5 mm
8 mm 2
maximum stress kO [MPa]

1000 1 mm
1200
3 mm
5 mm

maximum stress kO [MPa]

1 mm
800 1000 8 mm
2 mm
3 mm
5 mm 1
600 8 mm 800
2
3
values acc. to DIN EN 13906-1
600 5
400
8
Helical compression springs, shot
peened, made of oil hardened and values acc. to DIN EN 13906-1
400
200 tempered spring steel wire VDSiCr
with 1, 2, 3, 5 and 8 mm diameter
Helical compression springs, shot
Helical compression springs, shot
200 peened, made of oil hardened and
0 peened, made of oil hardened and
tempered spring steel wire TDSiCr
tempered SiCr-spring steel wire 1,
0 200 400 600 800 1000 1200 1400 1600 with 1, 2, 3, 5 and 8 mm diameter
2, 3, 5 and 8 mm diameter
minimun stress kU [MPa] 0
0 200 400 600 800 1000 1200 1400 1600

Fig. 5. Goodman-diagrams for shot peened helical minimum stress kU [MPa]

compression springs of oil hardened and tempered Fig. 6. Goodman-diagrams for shot peened helical
SiCr-alloyed spring steel wire VDSiCr, comparison compression springs of oil hardened and tempered
between fatigue test results for 10% failure SiCr-alloyed spring steel wire TDSiCr, comparison
probability (- - -) and DIN EN 13906-1 () between fatigue test results for 10% failure probability
(- - -) and DIN EN 13906-1 ()
The fatigue ranges of the VDSiCr test springs are
1600
relatively close together for low minimum stresses.
Springs with 2 mm wire diameter reach a higher fatigue 1400

limit than springs with 1 mm wire diameter, which is fatigue test results for wire diameters d =

1200
supposed to be an effect of shot peening with different 1 mm

intensity.
maximum stress kO [MPa]

2 mm
1000
Analogous to fig. 5 the following fig. 6 to fig. 10 3 mm
5 mm
show Goodman-diagrams illustrating test results for a 800

failure probability of 10% and corresponding standard values acc. to DIN EN 13906-1

600
Goodman-diagrams from Standard DIN EN 13906-1.
Fig. 6 represents Goodman-diagrams for shot peened 400
and pre-set helical compression springs of oil hardened
Helical compression
Helical compression springs,
springs, shot
shot
and tempered SiCr-alloyed spring steel wire TDSiCr in 200 peened, made
peened, made of
spring steel
of oil
patented
hardened
wire DH with
drawn
and
tempered SiCr-spring steel1,wire
2, 3,1,
5 diameters from 1 to 8 mm (upper horizontal lines and
2, 3, 5 mm
and diameter
8 mm diameter

0
limited to 0,6 x tensile strength). Compared to VDSiCr- 0 200 400 600 800 1000 1200 1400 1600
springs the fatigue range of TDSiCr-springs is a little minimum stress kU [MPa]

bit lower. Again springs with 2 mm wire diameter reach Fig. 7. Goodman-diagrams for shot peened helical
a higher fatigue limit than springs with 1 mm wire compression springs of patented cold drawn unalloyed
diameter. spring steel wire DH in 4 diameters from 1 to 5 mm,
Fig. 7 shows Goodman-diagrams for peened and pre- comparison between fatigue test results for 10% failure
set helical compression springs of patented cold drawn probability (- - -) and DIN EN 13906-1 ()
unalloyed spring steel wire DH in 4 diameters from 1 to

102
 1600 1600

1400 1400

fatigue test results for wire diameters d = fatigue test results for wire diameters d =
1200 1200
1 mm 1 mm
maximum stress kO [MPa]

maximum stress kO [Mpa]

1000 2 mm 1000 2 mm
3 mm
3 mm
800 5 mm 800
8 mm 5 mm

600 600 values acc. to DIN EN 13906-1

values acc. to DIN EN 13906-1

400 400

Helical compression springs, shot Helical compression springs

peened, made of oil patented of stainless spring steel wire
200 200 X 7 CrNi 17-7 (1.4568)
drawn spring steel wire DM with
1, 2, 3, 5 and 8 mm diameter unpeened with 1, 2, 3 and
5 mm diameter
0 0
0 200 400 600 800 1000 1200 1400 1600 0 200 400 600 800 1000 1200 1400 1600
minimum stress kU [MPa] minimum stress kU [MPa]

Fig. 8. Goodman-diagrams for shot peened helical Fig. 9. Goodman-diagrams for unpeened helical
compression springs of patented cold drawn compression springs of stainless steel spring wire
unalloyed spring steel wire DM in 5 diameters from X7CrNiAl17-7 (1.4568), comparison between fatigue
1 to 8 mm, comparison between fatigue test results test results for 10% failure probability (- - -) and DIN
for 10% failure probability (- - -) and DH-Goodman- EN 13906-1 ()
diagram of DIN EN 13906-1 ()
1600

Fig. 8 represents Goodman-diagrams for shot peened 1400

and pre-set helical compression springs of patented cold

1200
drawn unalloyed spring steel wire DM in 5 diameters
fatigue test results for wire diameters d =
from 1 to 8 mm (upper horizontal lines limited to 0,5 x
maximum stress kO [MPa]

1000 1 mm
tensile strength) in comparison to DH-Goodman- 2 mm
diagrams of standard DIN EN 13906-1, because no 800 3 mm
5 mm
DM-Goodman-diagrams are offered in this standard.
600
The test results for springs made of DH or DM are
values acc. to DIN EN 13906-1
nearly the same, which was also confirmed by other 400
fatigue tests. Springs with 2 mm wire diameter made of Helical compression springs
of stainless spring steel wire
both wire grades again reach a higher fatigue limit than 200 X 10 CrNi 18-8 (1.4310)
unpeened with 1, 2, 3 and 5 mm
springs with 1 mm wire diameter. diameter
0
Fig. 9 shows Goodman-diagrams for unpeened 0 200 400 600 800 1000 1200 1400 1600
minimum stress kU [MPa]
helical compression springs of stainless spring steel
wire X7CrNiAl17-7 with diameters from 1 to 5 mm. Fig. 10. Goodman-diagrams for unpeened helical
(upper horizontal lines limited to 0,6 x tensile strength) compression springs of stainless steel spring wire
in comparison to -Goodman-diagrams of standard DIN X10CrNiAl18-8 (1.4310), comparison between fatigue
EN 13906-1. Fig. 10 represents Goodman-diagrams for test results for 10% failure probability (- - -) and
unpeened helical compression springs of stainless standard DIN EN 13906-1 ()
spring steel wire X10CrNi18-8 with diameters from 1
to 5 mm. (upper horizontal lines limited to 0,5 x tensile It is obvious, that there are significant differences
strength) in comparison to Goodman-diagrams of DIN between the test results (failure probability: 10% ) for
EN 13906-1. shot peened springs from VDSiCr, TDSiCr, DH and

103
 DM and the standards values for corresponding springs, stainless steel wire X10CrNi18-8
1200
even taking into account, that the test results do not yet MPa DIN EN 13906-1, d = 2 mm test results, d =2 mm
include any safety aspects. 1000

In the last two Goodman-diagrams (fig. 9 and fig. 10) 800

for stainless spring steel wire grades, however, the

600
differences between the test results (failure probability:
10%) for not peened springs from stainless steel wires 400

and the standards values for corresponding springs are 200

not significant. This can be explained by the surface

0
condition of the stainless steel wires with small defects 1.4310 1.4568 DM DH TD VD
unpeened unpeened shot peened shot peened shot peened shot peened
from wire drawing. Reference fatigue tests on shot
peened springs made of stainless spring steel wires Fig. 11. Comparison between fatigue range values
(with a wire diameter of 1 mm) pointed out an according to standard DIN EN 13906-1 and test results
improvement of the fatigue range of nearly 50% by shot (fatigue range kO90% for 10% fracture probability) for
peening. springs with 2 mm wire diameter at ku = 0

2.5 Discussion of the fatigue range results
As already mentioned, the Goodman-diagrams (fig. 5
to fig. 10) are drawn with an upper limit of 0,5 x tensile
strength for springs made of DM, DH and
X7CrNiAl17-7 and with an upper limit of 0,6 x tensile
strength for springs made of VDSiCr, TDSiCr and
X10CrNi18-8. Therefore the upper limit of the
diagrams is mainly influenced by the tensile strength. A
measure for the fatigue range of the springs tested in the
region of lower minimum stresses is the ascending line
of the Goodman-diagrams. A comparison between the
test results (fatigue range or endurable maximum stress
with a failure probability of 10%) at a minimum stress
near 0 and the corresponding values in DIN EN 13906-
1 shows, that the experimental results generally exceed
the values of DIN EN 13906-1. The differences are
about 300 to 400 MPa for shot peened springs
made of oil hardened and tempered VDSiCr-
wire
about 300 to 400 MPa for shot peened springs
These differences are demonstrated in fig. 11 in terms
of absolute numerical values exemplarily for springs
with 2 mm wire diameter. Fig. 11 represents a
comparison between fatigue range values according to
standard DIN EN 13906-1 and test results (fatigue
range kO10% for 10% fracture probability) for springs
with 2 mm wire diameter for a minimum stress ku = 0.
Within one group of spring material the fatigue ranges
are different dependent on various wire diameters and
corresponding tensile strengths. If the fatigue ranges of
springs from one material are divided by the diameter-
corresponding tensile strengths, the results (strength
related fatigue ranges kO10%/Rm (test results) or kO/Rm
(standard)) are located close together in a relatively
narrow scatter band.
kO0 / Rm
0,6
relations kO(ku=0) / Rm according to DIN EN 13906-1
0,5 relations kO(ku=0) / Rm according to test results
0,4
0,3

made of oil hardened and tempered TDSiCr- 0,2

wire 0,1

about 200 to 350 MPa for shot peened springs

0,0
made of patented cold drawn steel wire DH 1.4310 1.4568 DM DH TD VD
unpeened unpeened shot peened shot peened shot peened shot peened
about 200 to 300 MPa for shot peened springs
made of patented cold drawn steel wire DM Fig. 12. Comparison between strength-related fatigue
about 80 to 100 MPa for unpeened springs range values kO/Rm according to standard DIN EN
made of stainless steel wire X7CrNiAl17-7 13906-1 and test results kO10%/Rm) at a minimum
about 50 MPa for unpeened springs made of stress ku = 0 for all springs tested.

104
 Fig. 12 shows a comparison between strength-related
fatigue range values kO/Rm according to standard DIN
EN 13906-1 and test results kO10%/Rm at a minimum
stress ku = 0 for all springs tested.
3. RESULTS OF ULTRA-HIGH-CYCLE FATIGUE
TESTS ON HELICAL COMPRESSION SPRINGS
The so called fatigue limit has currently become
the object of numerous discussions and more recent
investigations,20-22) e.g. through ultrasonic fatigue tests.
These tests prove that S-N diagrams of some materials
springs made of Si-Cr-alloyed valve spring wires with
wire diameters of 3 and 5 mm proved, that spring
fractures occurred up to high numbers of cycle, and
therefore the fatigue limit evaluated after 107 cycles
decreased distinctly (about 10 %) when it was evaluated
after 108 cycles for the same kind of test springs.
Furthermore the fatigue tests exhibited, that it is
necessary to replace broken springs by new springs
immediately in order to keep the test conditions as
constant as possible.
2000

do not exhibit any fatigue limits in the range of ultra- helical springs, shot peened, SiCr-alloyed
Pb [%]: 90 valve spring steel with 2 mm diameter
high cycle fatigue (UHCF). They also show, that even f=20Hz, R=0,06
50

corrected stroke stress [MPa]

in the case of stress amplitudes below the 10

conventionally determined fatigue strength, fatigue 0

1000
8
fractures still tend to occur in the UHCF range.23) They 900
k=5 8
furthermore prove that the crack initiation in the HCF- 800 8
8
700
range predominantly originates from the surface,
600
whereas in the UHCF range it mainly starts underneath
the surface, in particular, from internal inhomogeneities, 500
5
10 10
6
10
7
10
8
10
9 10
10

e.g. from inclusions. Broadly comparable results have number of cycles [N]

been presented in numerous other publications.24-28)
Some types of technical spring elements, especially
such as valve springs or springs in fuel injection
systems, are claimed to survive a very high number of
cycles with high mean stresses as well as high
amplitude stresses.
After having completed the investigation to
determine Goodman-diagrams, it was of remarkable
interest to carry out long term fatigue tests on helical
compression springs. This interest was initiated by
publications about ultra-high cycle fatigue tests on
specimens, hints on failure of components in the very
high stress cycle regime and by similar phenomena ob-
served by a working group of the Association of
German Springs Industry (VDFi - Verband der
Deutschen Federnindustrie) at long-term fatigue-
stressed helical springs. Within the long-term fatigue
investigation fatigue tests on selected springs were
carried out at a usual spring testing frequency of 20 Hz.
Short-term and long-term fatigue tests were
comparatively and statistically evaluated according to
the arcsin p-method. As a result S-N curves for
fracture probabilities of 10, 50 and 90% were received.
The fatigue tests on shot peened helical compression
Fig. 13. S-N-curves for failure probabilities of 10, 50
and 90 % for helical compression springs, evaluated
after 107 cycles.
In this report preferably one fatigue test run shall be
presented since it comprises the greatest range of cycles
as yet. Subjects of this fatigue test were shot peened
helical compression springs of Si-Cr-alloyed spring
steel wire with diameter of 2 mm, a spring diameter of
12 mm and a free length of 50 mm.29) Earlier fatigue
tests on these springs (covering 6 stress horizons with 8
springs on each horizon) up to 107 cycles lead to the
results shown in Fig. 13. At stroke stresses of 1212,
1132 and 1050 MPa all 8 springs failed between 106 and
107 cycles; whereas no fractures occurred at a stroke
stress of 972 MPa or below. By statistical evaluation
according to the arcsin p-method the fatigue limits
(stroke stresses) for 107 cycles are calculated to 1038,
1006 and 972 MPa for failure probabilities of 90, 50
and 10 %.
In Fig. 14, the data from fig. 13 are displayed and
complemented by the results of a long-term fatigue test
run with springs of the same kind. Based on the earlier
results, only the stroke stress horizons with 972, 892,

105
 812 and 732 MPa, which previously had not suffered About 35 fractures of test springs, which occurred in
any spring fracture up to 107 cycles, were loaded with the range between 10 and 700 x 106 cycles, were
16 test springs each. In fig. 14 only the life cycles of investigated by stereo microscope and SEM. This
those 16 springs per horizon are represented, which investigation proved:
were mounted at the beginning of the test. The crack initiations mostly manifest on the inner
On the stress horizon with 972 MPa the first fractures coil surface.
occurred after approximately 14, 23 and 24 x 106 cycles, Beyond 107 cycles most of the cracks initiate
and the last one of the originally installed test springs underneath the wire surface.
on this horizon broke after 121 x 106 cycles. After Often a characteristic form of the crack initiation is
approximately 1,5 x 109 cycles some 600 fractures were to be observed underneath the wire surface (Figs. 15
registered for the 16 test positions of this stress horizon, and 16). Thus, a clear centre of crack initiation which
among these also four with less than 107 cycles till possibly corresponds to one or more grain boundary
fracture. The mean value of the fatigue life at this stress areas arranged in nearly the same position is discernible
level is 36 x 106 cycles. at a depth of approximately one tenth of a millimetre.
2000
helical springs, shot peened, SiCr-alloyed
valve spring steel with 2 mm diameter
Pb [%]: 90 f=20Hz, R=0,06
50
corrected stroke stress [MPa]

10
*
k =30

1000
k=5
900 0
800
T=1:1,2 7
16
700
16
600

500
4 5 6 7 8 9 10 11 12
10 10 10 10 10 10 10 10 10
number of cycles [N]

Fig. 14. S-N curves for 10, 50 and 90 % survival

probability for shot peened helical compres- sion
springs of Si-Cr-alloyed valve spring wire with d = 2
mm (evaluated after 7 x 108 cycles).

On the next lower horizon with a stroke stress of 892

MPa, the first spring fracture occurred after 109 x 106
cycles, the last one, 1,49 x 109 cycles. All the original
16 test springs have broken after 1,5 x 109 cycles. On
the horizon following underneath with 808 MPa, 9
springs out of 16 have failed up to 1,5 x 109 cycles.
Statistical evaluation of the long-term fatigue test
according to the arcsin p-method leads to fatigue
limits (stroke stress) for 1,2 x 109 cycles of 886, 830 Fig. 15. Overview and detail of the Crack initiation
and 774 MPa for a failure probability of 90, 50 and zone of a shot peened helical compression spring (d = 2
10 %. Compared to the fatigue limit evaluated for 107 mm, Si-Cr- alloyed valve spring wire), stroke stress kh
cycles that means a decrease of more than 20 % of the = 890 N/mm, fracture after 112 x 106 cycles
fatigue limit for a failure probability of 10 %.

106

Fig. 16. Overview and detail of the Crack initiation
zone of a shot peened helical compression spring (d = 2
mm, Si-Cr- alloyed valve spring wire), stroke stress kh
= 808 N/mm, fracture after 88 x 106 cycles.
4. SUMMARY AND CONCLUSIONS
This report represents results of numerous fatigue
tests (till 107 cycles) on helical springs with diameters
from 1 to 8 mm, made of six different spring steel wire
grades. The fatigue ranges of the test springs are
demonstrated as Goodman-diagrams and compared to
given Goodman-diagrams in DIN EN 13906-1. This
comparison shows, that the test results (for a failure
probability of 10%) for shot peened springs made of
VDSiCr, TDSiCr, DH and DM are significantly higher
than the standards values for corresponding springs,
even taking into account, that the test results do not yet
include any safety aspects. For unpeened springs made
of two stainless spring steel wire grades, however, the
test results (again for a failure probability of 10%) were
not remarkably higher than the standards values for
corresponding springs.
After having completed these fatigue investigations
limited at 107 cycles, some long term fatigue tests on
shot peened helical compression springs were operated,
in one case up to a maximum number of 1,5 x 109
cycles. The fatigue range of shot peened helical
compression springs made of oil hardened and
tempered Cr-Si-alloyed spring steel wires shows a
significant decrease in the extremely high cycle region.
Further investigations are necessary to better
understand and possibly prevent these failures.
5. REFERENCES
1) P. Hora and V. Leidenroth, Qualitt von Schrauben-
federn. (Quality of helical springs). Dr. Riede
Verlag, Stuttgart (1987)
2) M. Bacher-Hchst, W. Haydn and G. Auweder, in
DVM-Bericht 669: Federn im Fahrzeugbau (DVM-
report 669: Springs in vehicle manufacturing), ISSN
0946-5987, pp 99-107
3) F. Fischer, M. Plitzko, G. Savaidis and K. Wanke, in
see 2), pp 9-24
4) P. Valentin, C. Bruch, G. Ney and A. Blsius, in
Federn unverzichtbare Bauteile in der Technik,
VDI-Berichte 1977 (2006) (Springs-unavoidable
components of technique, proceedings of a VDI-
Conference at Fulda / Germany, 7. and 8. of
November 2006, ISBN 3-18-091972-8, pp 27-391
5) H. Wei, M. Struckmeier, Ch. Bilgen, B. Ditzer, J.
Neubrand and A. Kleeman, in see 4), pp 55-71
6) Chr. Bilgen, Induktive Vergtung und thermome-
chanische Behandlung torsionsbeanspruchter SiCr-
Federsthle. Dissertation, Universitt GH Siegen
(1998)
7) R. Kaspar and A. Peters, in see 2), pp 245 253
8) A. Peters, Verbesserung der mechanischen Eigen-
schaften von Federsthlen durch Mikrolegierung
und thermomechanische Behandlung. Dissertation
RWTH Aachen (1997), Umformtechnische Schrif-
ten, Band 69, Shaker Verlag Aachen (1997)
9) Th. Berntsson and M. Jarl, Steel research int. 77
(2006) pp 836-843
10) L. Manke, in see 2), pp 35-43
11) DIN EN 10270, Stahldraht fr Federn. Teil 1:
Patentiert-gezogener unlegierter Federstahldraht;
Teil 2: lschluvergteter Federstahldraht; Teil 3:
107
 Nicht rostender Federstahldraht. (Steel wire for
mechanical springs. Part 1: Patented cold drawn
unalloyed spring steel wire); Part 2: Oil hardened
and tempered spring steel wire; Part 3: Stainless
spring steel wire.) Beuth Verlag GmbH, Berlin, 2001
12) P. Valentin and A. Blsius, in see 2), pp 219-244
13) D. Kirk, The Shot Peener, Volume 18, Issue 4, pp
24-28
14) P. Hutmann, The Shot Peener, Volume 18, Issue 3
(2004), pp 4-9
15) V. Schulze, in see 2), pp 45-54
16) H. Salm and Th. Heiderich, in see 2), pp 77-86
17) K. Kloos and B. Kaiser, Draht 28 (1977), pp 415-
421 and 539545
18) DIN EN 13906: Zylindrische Schraubenfedern aus
runden Stben und Drhten. Berechnung und
Konstruktion. Teil 1: Druckfedern (Cylindrical
helical springs made from round wire and bar
Calculation and design Part 1: Compression
springs. Beuth Verlag, Berlin, 1:2002
19) B. Kaiser, Draht 53 (2002), pp 48-53
108
20) H. Mughrabi, HTM 56 (2001), pp 300-303
21) J. Awatani, Mem. Inst. Sci. Ind. Res. Osaka
University 32 (1975), pp 71-85
22) S.E. Stanzl-Tschegg, H. R. Mayer, A. Beste and S.
Kroll, Int. J. Fatigue 17 (1995), pp. 149-155
23) C. Bathias, Fatigue Fract. Engng. Mater. Struct. 22
(1995), pp. 559-565
24) T. Sakai et al, in Fatigue `99, Proc. Of the 7th Int.
Fatigue Congress (1999), pp. 573-578
25) Y. Murakami, N. N. Yokoyama and J. Nagata, in
Proc. of Int. Conference on Fatigue in the Very High
Cycle Regime (2001), pp. 11-22
26) K. Shiozawa, L. Lu, Fatigue Fract. Engng. Mater.
Struct. 25 (2002), pp. 8131-822
27) L. Manes, G. Baudry, C. Bathias, S. Rathery, J.-F.
Vittori and J.-P. Doucet, in see 25), pp. 173-180
28) M. Nakajima, K. Tokaji, H. Itoga and N.-N. Ko, in
see 25), pp.181-190
29) C. Berger and B. Kaiser, in Proceedings of the Third
International Conference on Very High Cycle
Fatigue (VCF-3), September 16-19, (2004),
Ritsumeikan University, Kusatsu, Japan, pp 342-349