E-BOOK

ASK THE EXPERT -

WAVE SPRING FAQ

Smalley
engineers
answer
commonly asked
wave spring
questions.

smalley.com/wave-springs

THE ENGINEER’S CHOICE ™

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TABLE OF CONTENTS

Overview
Introduction and Benefits...........................................................................................................3

Performance
Compression/Load...................................................................................................... 4
Helical Coil Comparison....................................................................................................6
Stacking........................................................................................................................ 8

Measurement
Free Height..........................................................................................................................9
Work Height.......................................................................................................................10
Cycle Life ........................................................................................................................... 11
Tolerance ...........................................................................................................................12
OD Measurement............................................................................................................ 13

Design
Design Features ...............................................................................................................14
Number of Turns ..............................................................................................................16
Size ..................................................................................................................................... 17

Material
Temperature and Exotic Materials .........................................................................18
Spring Rate and Stainless Steel ..............................................................................19

Applications
Bearing Preload ................................................................................................................20
Lock Washer Replacement .............................................................................................21
Industry Examples ..........................................................................................................22

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OVERVIEW
Introduction & Benefits of Wave Springs

Overview
Wave springs are a type of compression spring made of flat wire. They are manufactured by coiling on
edge, also known as edgewinding.

The name “wave spring” comes from the multiple waves per turn. The Crest-to-Crest design can offer
the same spring force as a traditional coil spring, but at a reduced operating height. A reduction in
the spring operating height also decreases the spring cavity, and therefore, the overall assembly size.
Significant cost savings may be realized with a smaller, more light-weight assembly.

The wave spring technology is utilized across many different industries and various applications. From
rockets, preloading bearings, to consumer products like smartwatches, wave springs are the trusted,
precision-engineered solution for tight axial spaces.

Top 5 Reasons to Use a Wave Spring

1. Reduce axial space by up to 50%, resulting in
an overall decrease in assembly size, weight,
and cost.

2. Design flexibility - quick and

economic customization with Smalley’s
edgewinding manufacturing process.

3. Accurate and predictable load

configuration at working height.

4. Versatility – wave spring technology

can be utilized across many different
industries and applications.

5. Exotic alloys available to withstand practically

any extreme environment.

Standard or Custom?
• Over 4,000 standard springs in carbon and stainless steel (.188 in. - 16 in., 5 mm - 400 mm diameters)
• No Tooling Charges™ on custom designs (.157 in. - 120 in., 4 mm - 3000 mm diameters)

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PERFORMANCE
Compression/Load

Can springs be under load where the ends are not parallel when compressed?
Crest-to-Crest Wave Springs are designed to be compressed with a relatively even or parallel axial
load. If the ends are not parallel, the turns on the spring could slide to compensate for the unbalanced
load, thus leading to misalignment of the spring. This misalignment would lead to poor wave spring
performance. Smalley engineers would be happy to discuss the need for this type of design and help
find a solution for your application.

What does overloading do to springs?

The impact of overloading varies based on the overall size of the spring, spring material, number
of cycles, and the amount of load applied. All of our standard springs are designed to meet a load
requirement at the listed work height. If you have an application where the spring will see a higher load
than what is listed in the catalog, there is a possibility that the spring will become overstressed and take a
set. Entering your design into the Design a Custom Wave Spring tool can help demonstrate this concept.
However, we recommend contacting Smalley Engineering for a more in-depth understanding of the
impact and implications of overloading in your specific case.

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PERFORMANCE
Compression/Load

Can wave springs be compressed to flat for extended periods?

We do not recommend compressing any spring to solid for any duration of time, but Smalley has
designed springs that can operate in these conditions. Please contact Smalley engineering to discuss
your application in more detail.

When a wave spring is compressed, does its diameter increase? What happens to the spring load at work
height if the outside diameter is confined?
The diameter of a wave spring grows as it
is compressed. This is also referred to as
diameter expansion, and all Crest-to-Crest®,
Gap, Overlap, Nested, and WAVO® springs
will function in this manner. (As a side note,
linear springs will grow in length as they are
compressed.) If a spring is compressed to the
point that it contacts the bore, the spring
will bind. Binding causes the spring to
become rigid, and the spring properties,
as a result, become unpredictable.
Some Smalley wave springs, such as
the SSB series shown here on the right,
are designed to be constrained on the
outside diameter. Unlike a wave washer,
the spring can grow without binding
due to the presence of the gap or
overlapping ends. This interference fit, or
cling, assists with assembly and does not
significantly impact the load at the specified
work height. However, Crest-to-Crest and
Nested wave springs will bind if the outer
diameter of the spring contacts the bore.

It is always best to contact a Smalley engineer

with any applications in which you have
questions regarding an interference fit.

How does spring performance change over time in a static application?

Typically, a spring’s performance will not change over time in a static application.
However, if a spring is being compressed close to solid or is operating at a temperature greater than the
recommended operating temperature, then it could experience some set, resulting in load loss.
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PERFORMANCE
Helical Coil Comparison

Can a wave spring replace a coil spring?

Wave springs can provide similar forces and loads as a traditional coil spring. They achieve this at down
to about half the height of a coil spring. Due to the space and weight savings, a wave spring cannot be
directly substituted for a coil spring in your existing application without reducing the size of the spring
cavity. Wave springs must be designed into your application in order to realize all of the benefits.

Can a wave spring be made with the same or higher spring rate, compared to a helical coil spring?

Yes, we can increase spring rate with various modifications such as the number of waves, material
thickness, and number of turns. Crest-to-Crest springs can function similarly to helical springs in a variety
of applications. Smalleys engineers can help you identify the correct wave spring for your specific design
requirements.

Are wave springs cheaper than coil springs?

Wave springs can save you money when taking the whole assembly into consideration. Crest-to-Crest
Wave Springs allow for smaller assemblies with a reduced spring height, which results in a smaller
spring cavity. This translates into considerable cost-savings for the surrounding assembly, resulting in a
net savings that far outweighs the cost variance between the wave spring and coil spring.
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PERFORMANCE
Helical Coil Spring Comparison

I have four pocketed coil springs that load a coupling connection. Can wave springs be used to replace
the coil springs in this application?

Wave springs can serve as a replacement for coil springs in many applications.
For a coupling connection, a single wave spring can be designed to work along the circumference of the
housing and remove the need for pocketed springs entirely. Smalley may be able to offer a standard,
off-the-shelf item that can serve this need. Contact Smalley engineering with an assembly drawing for
engineering design assistance.

I’m using a coil compression spring in my assembly and want to switch to a wave spring design to help
with space savings.
What do I need to know in order to find the wave spring best suited for my application?

Since a wave spring is typically not a direct replacement for a coil spring, a good place to start is to
provide us with the parameters in which the wave spring will be working. To help with this, a spring
application checklist can be filled out - “Download an Application Checklist”. Once returned to Smalley,
an engineer will contact you to discuss your application.

Can you create a lower rate spring like a helical coil spring?
Smalley is capable of matching the spring rate of coil springs in most cases. Our engineering support is
available for specific design questions.
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PERFORMANCE
Stacking

Is it possible to stack wave springs as you might stack disc springs or do they require solid contact points
on each end?
Yes, Single-Turn Gap-Type wave springs can be stacked to achieve similar characteristics to disc springs.
Similar to a Nested Wave Spring design, wave springs can be stacked to increase the spring rate. To
decrease the spring rate and increase deflection, Single-Turn wave springs need to be stacked with
a shim separating each spring, which simulates a Crest-to-Crest wave spring. Stacking increases the
number of moving parts required to perform a function.
Many of our customers prefer to use one spring to get the spring characteristics they require and not
have to orient multiple parts in a specific pattern like what is required by disc springs because this could
lead to mistakes during assembly. If you have a situation where stacking is required, you may want to
consider using a custom design to meet your specific needs.

Will stacking two linear springs on top of each other double the load at work height?
Stacking two linear springs on top of each other would essentially double the load, but the work height
would have to be adjusted for the thickness of the extra wire. There are other possible issues that could
arise when stacking two or more linear springs. An alternative to stacking would be a linear spring that
is custom-designed to fit within the required work height while still meeting the load requirements.
A Smalley engineer would be happy to discuss that design with you.

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MEASUREMENT
Free Height

How do I measure the free height of a wave spring?

It’s important to know to how to properly measure a wave spring’s free height in order to verify that
you are using the correct part for your application. When done correctly, it can also save you valuable
inspection time.

How to Measure the Free Height of a Wave Spring:

1. Ensure that the spring is sitting on a flat surface between two parallel plates.
2. Lower the top measuring surface until it makes contact with the top of the spring.
3. Apply a slight force to deflect the spring until the crests of all the waves come in
contact with the loading surfaces (top and bottom).
4. The distance between the two parallel plates is the free height.
Click below to watch a video:

Important Definitions:

Free Height: The height at which a wave spring is measured in its free state
Work Height: The designed height at which a desired force/load is delivered

It is also important to note - the free height of a wave spring is typically a reference dimension.
Wave springs are normally designed to provide a specific toleranced load at a given work height.
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MEASUREMENT
Work Height

I am considering using the SSR-0225 model wave spring. Your website states, “the calculated spring rate is
linear through the first 80% of available deflection.”
Is the available deflection the free length minus the work height?
For example, this spring’s available deflection is .170 (free height) - .093 (work height) = .077 inches?
No. The available deflection refers to the range between the free length and the solid height. The free
height is approximate, therefore, so is the spring rate and available deflection.

Smalley standard springs are inspected only at the load at the work height specified in the catalog. For
example, the SSR-0225 is checked at a work height of .093 inches.

While the spring may work at other heights, it is best to contact our engineering department to evaluate
the theoretical spring characteristics at an alternate height.

Nomenclature:
f = Deflection, in
WH = Work height, in (H-f)
H = Free height, in

What is the minimum work height of part CM20-L1 if made with carbon steel SAE 1070-1090? What is
the load at that height?
This specific part was designed to be compressed to a work height of 2.72 mm to achieve a load of
35 ± 3.5 N.

We typically do not recommend compressing the spring below this designated height, but it is
generally better to speak with Smalley engineer about this. Depending on how the wave spring is being
used in your application, they would be able to determine whether it would be appropriate to use this
spring or find you a new wave spring solution.
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MEASUREMENT
Cycle Life

Can you provide cycle life data? Cycle Tester:

Yes, we can estimate the theoretical cycle life of

our springs using a series of special equations.

Note that theoretical cycle life estimates are just

that — estimates. There are a number of variables,
including variables specific to the use that your
springs will be put to, that will affect the true cycle
life.

The theoretical cycle life equation can be found

in our catalog or at Smalley.com/engineering. You
can also contact a Smalley engineer to discuss the
specific application parameters of your spring.
Smalley also offers cycle testing as an option.

Formula:

σ = Material tensile strength

S1 = Calculated operating stress at lower work height
S2 = Calculated operating stress at upper work height

Table:

Fatigue Stress Ratio Fatigue Stress Ratio

.00 < X < .40 under 30,000 cycles
.40 < X < .49 30,000 - 50,000 cycles
.50 < X < .55 50,000 - 75,000 cycles
.56 < X < .60 75,000 - 100,000 cycles
.61 < X < .67 100,000 - 200,000 cycles
.68 < X < .70 200,000 - 1,000,000 cycles
.70 < X over 1,000,000 cycles

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MEASUREMENT
Tolerance

When spec’ing a wave spring, what is diameter tolerance on a bore or shaft?

Every spring has two diameter measurements, the shaft diameter and the bore diameter.
The shaft and bore diameters are the actual bore and shaft diameters of the assembly that create the
cavity the spring works within.

The tolerance of a bore or shaft diameter depends on customer capabilities. We design in

enough clearance to allow for standard manufacturing practices, so holding to these tolerances is
recommended.

What is the tolerance on spring rate?

The spring rates (load ÷ deflection), as listed in the catalog, are reference values. Other characteristics
of the spring, such as wire thickness, free height, and radial wall, can affect this value. The spring rates
for our wave springs tend to have constant rates from approximately 20% to 80% deflection. As the
spring approaches its solid height, the rate typically grows exponentially and is no longer linear. For this
reason, we tolerance loads at specified work heights as this is a measurable and more accurate way of
determining the functionality of our springs.

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MEASUREMENT
OD Measurement

How do you measure the outer diameter of a single turn wave spring?
Click below to watch a video on how to properly measure the outer diameter of a wave spring:

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DESIGN
Design Features

What are some overall design limitations on a Crest to Crest wave spring?
Smalley manufactures springs ranging in diameters from about .157 in. (4 mm), to 9.8 ft. (3 m), or more.
Possible design limitations vary and depend on a number of different design requirements, such as load,
deflection, free height, cycles, and so on. Contact a Smalley engineer to discuss potential designs and
limitations.

When trying to design a prototype to test in an application, why do we need to know what the load is at
two separate work heights?
Smalley does not necessarily need to know the loads at multiple work heights for every design. This is
primarily based on the application in which the spring is used. If the spring is meant to be static, then
the operating height is usually all that the Smalley engineer will need to know. However, for some static
applications, the spring can be compressed beyond the work height during installation. In this case, it
would be an important design consideration to know both the installation and operating work heights.
In a dynamic application where the spring is cycling between two heights, both the number of cycles
and the work heights need to be considered in order to develop the appropriate design solution.

It is helpful to provide as much information as possible on the Spring Design Checklist to get started
with your design. If you have questions about any of the terms, our Engineering Resource Section and
Glossary section can help define terms and equations.

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DESIGN
Design Features

Why do Smalley single turn springs have a gap? How is this better from a stamped washer?
Smalley products are manufactured by coiling, not stamping. Our edgewinding process allows us the
flexibility to add a gap or an overlap during manufacturing. A benefit of having a gap or an overlap is
that Smalley parts will operate and/or cling when contacting a bore, while stamped products would
bind while contacting a bore. Binding causes the spring to become rigid, and the spring properties, as
a result, become unpredictable. This allows Smalley parts to work in tighter radial cavities. Furthermore,
the edgewinding process results in our springs having a circular-grain metallurgy. The benefit of this is it
gives our products strength and stability far superior to that of conventional wave washers, providing a
more accurate, repeatable load.
What is the practical difference between overlapping and non-overlapping wave springs?
For the most part, Overlap and Gap-Type Wave Springs will perform similarly in the application. Both
are designed with free ends that allow the outside diameter to contact the bore without binding as the
spring is compressed. The overlap-type spring will have a higher solid height than the gap-type spring
due to the overlapping ends, but the overlapping ends will help prevent the springs from tangling as
much in the packaging. If you have any more concerns about the differences between gap and overlap
type springs and how they may impact your application, please contact Smalley engineering.

Are you able to develop a wave spring that goes through an arc of about 250° instead of a full circle?
Yes! Since our manufacturing process involves coiling flat wire on edge, we can control the amount of
wire that is fed into each part. This gives us flexibility with most dimensions of the spring, and in this
case, the ability to create a spring with a large gap. We can even create wave springs that are just a small
fraction of the overall circumference. For example, if you only need 10° of the full circle, similar to a linear
spring with a slight curve, we can create a custom design. If you let us know what you need, we will work
with you to meet your requirements.
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DESIGN
Number of Turns

What is the maximum number of turns for a nested wave spring? Can loads still be toleranced with this
many turns?
There is not a specific maximum number of turns for a nested spring, but every application is different.
A nested spring with many turns may work for one project, but not for another. Springs with a very high
spring rate, such as a nested spring, can be more difficult to tolerance the loads. Minor changes in the
wire thickness or free height in the spring from lot to lot can have a dramatic impact on the load. Our
Engineering team will review all new spring designs and discuss our capabilities with you.

Can I reduce the spring load in a Crest-to-Crest spring by cutting the spring turns?
This is a common question that has several answers, depending on how the spring is being used. If you
are looking to reduce the spring rate, cutting off turns would actually increase the spring rate and not
decrease it like intended. This is because the number of turns inversely affects the spring rate in the
Crest-to-Crest spring rate formula.

Multiple Wave Factor (K)

N 2.0 - 4.0 4.5 - 6.5 7.0 - 9.5 > 10.0
K 3.88 2.90 2.13 2.13

However, cutting off turns would likely reduce the load at a specific work height. This is because you’re
reducing the free height, and therefore, the travel between the work height and the free height, resulting
in a lower load. This reduction in load will likely happen even though the spring rate is higher with fewer
turns, as previously explained.

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DESIGN
Size

How small can a wave spring be manufactured and still function in my application?

If our smallest off-the-shelf .188 in. (5 mm)

diameter wave spring is too big, Smalley can
reliably edgewind custom Crest-to-Crest wave
springs with diameters as small as .157 in. (4 mm).
Depending on the necessary work height(s) and
load(s), such small wave springs could be a great
fit and perform well. At these small diameters,
and given the size of the wire relative to the
rest of the design and tolerances, every design
parameter can have a significant effect on the
final design’s performance. Smalley’s dedicated
engineering staff is available to discuss your
specific application and help you design the right
spring for your needs.

What is the biggest overall diameter you can design for a crest-to-crest wave spring?

Smalley can manufacture springs in diameters of up to about 120 in. (3 m). Such large wave springs
can be impractical except when very specific design requirements need to be met. Contact a Smalley
engineer to discuss your design needs to learn if a wide diameter spring is right for you.

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MATERIAL
Temperature and Materials

How do wave springs hold up to cryogenic temperatures? Will the spring rate change and are some
materials you offer better suited for these colder temperatures?
The spring rate increases when springs are subjected to cryogenic temperatures; however, the increase
is minimal. The modulus of elasticity for almost all steels only increases slightly from room temperature to
cryogenic temperatures, and in turn, the spring rate is minimally affected.

Not all types of steel are suited for cryogenic conditions. Certain alloys become brittle at very cold
temperatures and are not a good choice for a spring operating in cryogenic conditions. Some alloys
that Smalley customers have had success with are 302, 316, A-286, Inconel and Elgiloy. These alloys are
successful because they retain their microstructure in extremely cold temperatures. Copper alloys such
as beryllium copper and phosphor bronze can also work well for these applications.

Can you make a spring with Inconel X-750? With what other exotic materials can you make springs?
Smalley can manufacture wave springs in a variety of exotic alloys, including various types of steel,
coppers and, yes, Inconel X-750. Inconel X-750 is a NACE compliant exotic alloy that is commonly used in
oil and gas applications.

Remember that it is always best to choose a material based on the requirements of the application and
the usage environment. There are a variety of key factors when it comes to choosing the right material for
your application including environment, budget, and cycle life. Smalley stocks standard springs in carbon
steel and 17-7 stainless steel. To learn more about selecting an appropriate material for your application,
take a look at our Material Selection Guide.

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MATERIAL
Spring Rate and Stainless Steel

Would a spring manufactured in carbon steel have the same spring rate as a spring manufactured in
stainless steel?
Not necessarily. We can design a stainless steel spring to carry the same load at work height as a carbon
steel spring, however, the spring rate will be slightly different because you’re using a different material.
Our standards are designed to carry a load at a work height and our customs are also designed to be
able to meet that load and work height requirement.

Does Smalley have a product that can replace stainless steel wave washers? In my application, the
washers are too soft and flatten out under the load. What can you recommend?
Stainless steel has lower spring properties in comparison to spring tempered carbon steel. This is a
common concern for many engineers. Most engineers are accustomed to using 302 stainless steel for
springs, which does not have the same level of spring properties that spring tempered carbon steel
provides.

Smalley uses 17-7 PH, Condition CH900 stainless steel for our stainless steel springs. 17-7 has spring
properties that are very similar to spring tempered carbon steel and does not require the “20% less load”
rule that is usually applied to 302 stainless steel springs.

Smalley engineers can recommend a standard part or design a custom wave spring for you using 17-7 PH
stainless steel to meet your requirements.
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APPLICATION
Bearing Preload

Why should you use a wave spring for bearing preload?

Properly preloading a bearing extends the life of the bearing by eliminating play, vibration, noise, and
wear. There are two types of bearing preload: solid preload, which is achieved by holding inner and
outer rings in place with a locking mechanism, and the more common spring preload, which is achieved
by using a spring to apply a constant axial load. Spring preloading compensates for any misalignments
as well as thermal expansion or contraction. This essentially eliminates the need for holding tighter
tolerances and helps withstand high operating speeds. Smalley’s SSB Wave Spring series is carefully
designed for bearing preload applications.

Bearing without a preload. Bearing with a preload.

Which wave spring should I choose for my application?

Every application is unique, which makes
selecting the proper wave spring very
important. Smalley has a standard bearing
preload wave springs series (SSB), designed for
popular bearing sizes. Overall tolerances are
critical in this application, as placing too much
preload on the bearing can reduce longevity,
while too little can cause higher noise output in
high vibration systems.
Correct material selection is also vital, as the
incorrect material choice can lead to failure
in operation. While Smalley wave springs are
stocked in both Carbon Steel and 17-7 Stainless
Steel, we are able to offer wave springs in a
variety of alloys to meet your application’s
operating conditions. For more information,
reference our materials page.
If you do not see a material you are looking for,
please contact Smalley engineering.
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APPLICATION
Lock Washer Replacement

Can you use a wave spring to replace a lock washer?

Lock washers, also referred to as split washers, are used to prevents nuts and bolts from slipping or
turning in an application. The washer applies a light load to minimize the effects of vibration, keeping the
nut and bolt tightly in place. Lock washers are typically manufactured from low-cost materials to take up
tolerances.

When special alloys are needed for corrosive or high-temperature environments, custom lock washers
can be difficult to source and expensive to manufacture. Smalley’s Nested Wave Springs can be specified
as an alternative in these instances. However, a nested wave spring cannot be compressed down to a
solid without load loss, so it is best to speak to a Smalley engineer if this is an appropriate replacement in
your application.

Smalley’s Nested Series of Wave Springs are

coiled from spring tempered materials. The
coiling process reduces or eliminates scrap,
making the manufacturing process cost-effective
for Stainless Steel and other exotic alloys such as
A286 Stainless Steel, Elgiloy® or Inconel.

Nested Wave Springs also offer functional

benefits when compared to lock washers. These
springs are coiled in series, increasing the load
with each turn until the desired spring rate and
deflection are reached. With larger industrial
bolts, the wave springs can provide a more
evenly distributed force, keeping the stresses
uniform around the bolt head. Nested Wave
Springs can provide a more accurate, repeatable
load than a lock washer.

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APPLICATIONS
Industry Examples

What kind of unique applications is the wave spring technology in?

When examining potential uses for Smalley’s versatile wave springs, Aerospace, Automotive, and Medical
applications are usually the first to come to mind. Granted, there are probably thousands of designs
where wave springs are a viable solution, but that only scratches the surface of the capabilities of these
innovative products.

A unique application that utilizes wave spring technology is athletic shoes.

The performance of a quality athletic or casual shoe

is determined by the amount of shock absorption it
provides while being used. Typically, Smalley wave
springs are relied upon in high-load assemblies, so
it’s easy to see why they could be considered as a
solution as a shock absorber for the body.

Most manufacturing assemblies have weight

requirements, and in some instances, have
limited space for a conventional coil spring. These
conditions are very much like those found in the
sole of a shoe.

Smalley wave springs provide space-saving

capabilities in a very lightweight design. Wave
springs are roughly half the height of coil springs
while still providing the capacity to absorb the
heavy, repeatable loads created by a machining
turret or a jog around the neighborhood. The practical use in a shoe is an example of how the wave
springs are apt for both static (standing) and dynamic (running) purposes across a variety of processes.

Athletic shoes using wave spring technology showcases how Smalley products are used across different
industries, from casual consumer products to space exploration and everything in between. Custom
solutions are one of Smalley’s areas of expertise. Design considerations such as available space, intended
function, environment, and consistent performance are all factors that play significant roles in the design
process.

Please contact Smalley for more information on how wave springs could be the ultimate solution for your
project, regardless of industry.

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APPLICATIONS
Industry Examples

What kind of unique applications is the wave spring technology in?

Aerospace Electrical Connector

Two wave springs are compressed, exerting a
constant force on the connector, providing continuous
connection.

Auto Mirror
The Crest-to-Crest Wave Spring allows for the mirror to
adjust while remaining lightweight and small to reduce
assembly size.

Sprinkler Valve
The wave spring maintains constant pressure on the
pop-up head so it remains closed. In operation, water
pressure releases the head by overcoming the spring’s
force.

For a more application examples, visit our Applications page.

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Ask Smalley.
For over 50 years, Smalley has been
the world leader in the manufacturing
and development of precision
retaining rings and wave springs.

Smalley works with nearly every

industry, from aerospace, automotive,
medical, off-highway, oil & gas to
industrial.

With regional offices in the Americas,

Europe, and Asia, Smalley provides
total global supply chain solutions
to meet worldwide manufacturing
demand.

Ready to learn more?

We would love to hear from you.

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[email protected]