Wave Spring

Wave springs are used in applications where space is constrained, such as automotive transmissions, aerospace actuators, medical devices, and valve assemblies. They are specified by their outer diameter, inner diameter, free length, number of waves, and material. Grades differ by material (e.g., carbon steel, stainless steel, superalloys), precision (e.g., DIN 2098 for precision springs), and surface treatment (e.g., phosphate, passivation). They offer reduced solid height compared to conventional coil springs, making them ideal for compact designs. Wave springs are manufactured from flat wire, which allows for a lower solid height and more efficient use of space compared to round wire springs. The design converts axial load into radial deflection of the wavy coils, with the waves acting as multiple beams that bend under load. The spring rate is a function of wave height, material modulus, and cross-section. Typical materials include carbon steel (e.g., 65Mn, 60Si2MnA), stainless steel (e.g., 301, 302, 304, 316), alloy steel (e.g., 17-7PH, Inconel X-750), and beryllium copper (e.g., C17200). Key parameters include wire diameter (0.2–5.0 mm), outer diameter (5–300 mm), inner diameter (3–280 mm), free length (1–50 mm), number of waves (3–10), spring rate (0.5–500 N/mm), maximum deflection (15–40% of free length), operating temperature (-40 to 250°C), surface finish (phosphate, passivation, or oiled), dimensional tolerance (±0.05 mm per DIN 2098), load tolerance (±10% per DIN 2095), and fatigue life (10^6 cycles typical). Standards referenced include DIN 2098, DIN 2095, GB/T 1972, and ASTM A693. Always verify model-specific values and standards with the legal manufacturer or supplier before selection.

Wave springs operate by converting axial load into radial deflection of the wavy coils. The waves act as multiple beams that bend under load, providing a spring rate that is a function of the wave height, material modulus, and cross-section. The flat wire design allows for a lower solid height and more efficient use of space compared to round wire springs.