European Springs Web Team, Author at European Springs

In 2024, sustainability is more than just a moral choice for UK manufacturers—it’s also a business strategy that can drive growth, reduce costs, and secure a competitive edge in your market.

With the Labour government’s recent commitment to environmental protection through the NetZero 2050 initiative, there’s never been a better time to align your business goals and invest in sustainable practices with government support and strategic actions. This blog explores actionable steps relevant to sustainability and how they will help grow your business.

Eliminate Wasted Energy and Materials

One of the most immediate benefits of sustainable manufacturing is the reduction in energy costs. By implementing energy-efficient practices and technologies, manufacturers can significantly lower their operational expenses.

Investing in energy-efficient machinery and equipment can lead to substantial savings. While the upfront cost may be higher, the long-term reduction in energy bills makes it a smart financial move. For example, replacing outdated machines with energy-efficient models can reduce energy consumption by as much as 30-40%.

Another area to explore is encouraging employees to adopt material-saving actions or recycling efforts listed in the Waste Hierarchy. The concept is that every company will attempt to apply the highest step of the hierarchy to their waste scheme. They must only attempt the lower step if it is impossible to do the one above. So, for example, if prevention is not possible due to technical, financial or logistical issues, you try to reuse or recycle. Enforcing the waste hierarchy on your waste program is a national requirement. However, it is also a fantastic way of reducing your company’s carbon footprint.

We recommend conducting an internal review of your energy audit and current waste hierarchy. This will provide you with the information you need to make numerous small changes, such as installing motion sensor lighting, determining how high-energy machinery is used, and implementing more efficient recycling methods. These benefits will accumulate into large gains regarding company expenses, which then can be repurposed into new areas of growth.

Enhancing Brand Reputation and Growth Through Sustainable Practices

There are also external factors that will simultaneously support sustainability and brand growth. Incorporating Corporate Social Responsibility (CSR) into your sustainable manufacturing strategy can significantly enhance brand reputation and growth. By actively engaging in CSR initiatives, such as supporting local and ethical material sourcing, manufacturers can demonstrate a holistic commitment to sustainability.

As consumers and businesses increasingly prioritise environmental responsibility, manufacturers that commit to sustainability can stand out in a competitive market. Integrating CSR into your sustainability agenda not only strengthens your brand’s appeal but also positions your business as a leader in responsible manufacturing practices.

By implementing eco-friendly initiatives and sharing them in marketing materials, manufacturers can build a stronger, more positive brand image. These actions not only attract environmentally conscious consumers but also foster loyalty among existing customers who value sustainability.

Obtaining green certifications, such as ISO 14001 for environmental management, are excellent actions that will further elevate your company’s standing. These credentials serve as a powerful endorsement of your commitment to sustainability, making your business more attractive to potential customers and partners.

Align with the Net-Zero 2050 Initiative for Long-term Growth

The UK’s Net-Zero 2050 initiative is a national goal that no business can afford to ignore. Aligning your manufacturing processes with this initiative not only ensures compliance with future regulations but also positions your company as a leader in sustainable practices, which in turn provides the previously mentioned benefits in expenses and brand reputation.

Carbon offset programs are currently well-known as a solution. The concept of helping to fund green technologies to balance out the carbon-heavy actions of your business is working, but we believe that we are reaching a stage where manufacturers can transition to low-carbon processes and reduce their carbon offset costs.

This is partially because of the increasing number of UK government support programs. Several initiatives and funding opportunities are available in 2024 to assist manufacturers in adopting more sustainable practices, particularly through investments in renewable energy sources. These programs aim to foster innovation, promote economic growth, and support the UK’s transition to net zero. Here are some of the current ones, with more planned in the near future.

Green Industries Growth Accelerator (GIGA)

There is a committed £960 million announced to the Green Industries Growth Accelerator (GIGA). This funding is targeted at expanding the UK’s clean energy supply chains, providing manufacturers with significant opportunities for growth and innovation. This initiative is designed to help manufacturers take advantage of the growing demand for clean energy solutions, aligning with the UK’s broader decarbonisation goals. Key areas of support include:

Carbon capture, utilisation, and storage
Electricity networks
Hydrogen
Nuclear energy
Offshore wind

Industrial Energy Transformation Fund

In addition to GIGA, the government has announced a new £185 million fund as part of the broader Industrial Energy Transformation Fund. This funding is aimed at helping businesses, including manufacturers, implement eco-friendly upgrades. Eligible upgrades include:

High-efficiency insulation
Heat pumps
Solar panels

The fund is intended to support the transition to renewable energy, enabling businesses to replace inefficient equipment and adopt electric and hydrogen-based solutions.

Not all the planned support is in force yet, but they are worth monitoring as the new government is planning to enhance many additional options for our sector. Here are some examples rumoured to be on the horizon.

Made Smarter Adoption Program: Expanded to drive innovation in manufacturing processes with sustainable goals in mind.
Hydrogen Industry Taskforce: To support the development of hydrogen technologies that will create carbon-neutral fuel sources.
Advanced Manufacturing Plan: Strengthening the UK’s manufacturing capabilities without sacrificing sustainable goals.
Battery Strategy: The UK’s first Battery Strategy is expected to outline plans for a globally competitive battery supply chain by 2030, a new concept to hold excess energy creation and prevent waste.

We highly recommend staying informed about these initiatives as further details on application processes and eligibility criteria will be released. These efforts are part of the government’s continued NetZero strategy to enhance energy security and facilitate the shift to a low-carbon economy, which will undoubtedly mean significant changes per company to remain competitive.

Sustainable Manufacturing at European Springs

Sustainability in manufacturing is not just a responsibility to protect the environment, but it can also be an excellent tool for growth within a business. The increased funds gained when wasteful practices are removed are combined with a commitment to being eco-friendly to strengthen your reputation. As a result, your business has many new opportunities open to it, and therefore, as we’ve experienced, there are plenty of areas to grow into.

We recognise the critical importance of sustainability solutions here at European Springs and are dedicated to achieving our own NetZero goals. Our approach is rooted in responsible business practices, energy-efficient production, and transparent stakeholder engagement. We prioritise reducing emissions, offsetting our carbon footprint, and fostering a sustainable workplace where every employee plays a role. Through these efforts, we aim to not only enhance our operations but also inspire positive change across the wider industry.

Be sure to check in on our blog regularly, as we will regularly update it with important information about our industry from our position as leading spring manufacturers in the UK.

Engineering apprenticeships are excellent investments for both the student and the employer and provide many benefits to the UK manufacturing industry as a whole. The sector has long been struggling with a skills shortage due to a lack of new talent and the invention of increasingly complex technology, but engineering apprenticeships effectively combat these challenges.

This blog will share how the various engineering apprenticeships nationwide are excellent solutions for both aspiring engineering students and a sustainable way for manufacturers to grow their teams and their businesses overall.

UK South East Manufacturing Growth in 2024

Manufacturing across England has seen significant progress, with the latest Make UK Regional Snapshot Outlook 2024 showing improvement in our region, where our spring manufacturing facility is located.

Over the past year, the region has seen strong performance, with an output balance (the number of businesses that report an increase in production) averaging +20%, placing it among the top-performing areas nationwide. Orders to manufacturing businesses in our part of the country have also seen substantial growth, with a balance figure of +22%, indicating a healthy demand for UK manufactured goods.

While employment here hasn’t quite kept up with the national average—growing just 8% instead of the needed 9%—there’s good news. The government has put forward plans to help bridge this gap and support continued growth in the region. For example, various initiatives that fall under the larger umbrella of the National Engineering and Technology Workforce strategy are planned to support T-levels, enhance diversity in STEM workforces and promote apprenticeships.

UK Government Supporting Apprenticeship Growth

With engineering and technology set to expand rapidly by 2030 to meet the nation’s NetZero targets, there’s pressure to equip young engineering students with the necessary skills. To achieve this, the new Labour government is focusing on apprenticeships and tailored training opportunities to meet current demands and drive future innovations, including major projects like Great British Energy. This plan is aimed at increasing the UK’s energy security and sustainability by investing in a diverse range of green technologies and advanced technologies that will need young, intelligent engineers to understand. It focuses on increasing domestic renewable energy production, reducing reliance on fossil fuels, and fostering innovation in energy storage and grid management.

EngineeringUK and the National Engineering Policy Centre are advocating for a National Engineering and Technology Workforce Strategy. This strategy is essential for aligning education and training with industry needs, ensuring that young people are not only entering the workforce but are also equipped with the skills necessary to thrive.

With all this support, we predict that the labour and skills shortages that have challenged our industry will be a thing of the past, with many more young people seeing the benefits of joining our industry and many more employers seeing the benefits of this inclusion as we have for many years.

How Do Apprenticeships Support Businesses?

Engineering apprenticeships provide an excellent employment solution for UK manufacturers as they allow new talent to join an industry where skills gaps have been present in the past. They also give employers the opportunity to develop young engineers in line with the company’s demands at the time. For example, as technology and processes evolve, such as the invention of synthesised nanosprings, apprenticeship programs will adapt, keeping the potential workforce up-to-date with the latest industry advancements.

They also offer clear career progression and continuous learning opportunities, which increases employee loyalty. We’ve seen how apprenticeships not only lead to long-term employment but also contribute to a highly skilled workforce capable of meeting market demands. We believe that investing in apprenticeships is crucial for ensuring the future success and competitiveness of both our company and the manufacturing industry.

Engineering Apprenticeships at European Springs.

Every year, we at European Springs are glad to take on new aspiring engineers to support their growth and studies and eventually become valued members of our industry.

Our highly successful apprenticeship programme offers a unique opportunity for young engineers to earn while they learn. By combining the latest classroom instruction with experienced hands-on training, the apprentices who choose us gain the knowledge, skills, and experience necessary to become qualified engineers. This programme not only leads to an industry-recognised City & Guilds or BTEC qualification but also provides a direct pathway into a rewarding career in engineering. Many of our apprentices go on to secure full-time positions with us, continuing to develop their expertise and contribute to our success.

You’ll work alongside experienced professionals making the various products we sell, such as classic compression springs and pressings, learning by shadowing, conducting supervised work, and practical assessments. The flexibility of our programme allows you to grow at your own pace, with the potential to become fully qualified within 1-4 years.

We believe in investing in our nation’s future workforce and recognise the importance of supporting the growth of new talent. If you or someone you know is looking to start a profitable career in spring manufacturing, apply to our apprenticeship programme today and benefit from the solid foundation for a successful and fulfilling career in engineering.

Like many other industries, engineering and manufacturing are seeing an incredible acceleration in their processes thanks to the ever-growing presence and influence of artificial intelligence (AI). Whether it’s the automotive, medical, or power sectors, complex spring systems are employed to ensure the smooth functioning and safety of machinery, tools, and vehicles. Here, the design, prototyping, and testing of each component are indispensable but can be time-consuming and costly.

This is where AI steps in, driving innovation, reducing costs, and bringing a new level of efficiency to the spring design process. In this blog, we will discuss the latest developments in how AI is revolutionising the manufacturing industry through new methods, ranging from automated design optimisation to rapid prototyping and iteration.

The Power of Automated Design Optimisation

Among the most recent advancements within spring engineering, automated design optimisation emerges as one of the most transformative solutions offered by AI. Through complex AI algorithms, engineers are empowered to streamline the design process; they often identify the most effective spring configurations with great precision and navigate parameters like load capacity, stress distribution, and fatigue life in a fraction of the time usually spent. This proactive approach results in reduced design flaws, enhanced spring reliability, and elevated compliance with performance standards.

Whether AI will help or replace humans at their work is often debated; however, automated design optimisation is one clear example of how the two aspects go hand in hand and make engineers’ lives easier. Thanks to AI, their time is reallocated to focus on creative and strategic aspects of design while AI manages “less exciting” calculations and iterations. As leading spring manufacturers, we are positive this symbiotic relationship will promote continuous improvement.

Enhanced Performance through Innovative Material Selection

We have discussed many times how selecting the right material is a critical aspect of custom spring design, as the final choice will impact the performance, longevity, and overall application of the product for better or worse. AI technology turns out to be a precious ally as it significantly contributes to the right material choice. Let’s see how.

AI scans through large amounts of data to identify the best materials for each application, considering key factors such as strength, flexibility, fatigue resistance, and cost.
Engineers will use AI to predict how different materials will behave over time and in various conditions, allowing them to pick the best-performing ones to improve their durability and performance.
AI is predicted to help with developing tailored materials to suit specific requirements. This customisation guarantees that the final spring meets unique criteria that standard options cannot match.

All these substantial contributions lead to higher-quality products that better meet the needs of many different industries.

AI in Advanced Simulation and Testing for Spring Prototyping

AI-driven tools dramatically improved spring prototyping, implementing new simulation and testing processes and offering a thorough performance analysis of how springs behave under various conditions.

By replicating realistic scenarios with incredible accuracy, including different loads, temperatures, and environmental factors, these simulations allow engineers to understand better the spring types they are designing, ensuring that they are sturdy and reliable. What’s more, these advanced simulations often detect potential issues in the early stages and reduce the risk of costly failures during later development stages, or even actual use.

It is unbelievable to think that, previously, such a detailed level of analysis and testing was time-prohibitive; now, thanks to AI, not only is it possible, but it is also easily achievable and more efficient. Lastly, it is worth mentioning how AI also facilitates rapid and iterative testing of multiple design variations, which we will explore below in more detail.

Rapid Prototyping and Iteration in AI-driven Spring Design

With AI revolutionising so many aspects of traditional spring manufacturing, it comes as no surprise that prototyping and iteration are seeing significant upgrades, drastically reducing the time employed from concept to final product. We briefly mentioned how these processes are benefitting from increasing automation, now we will delve into them more specifically.

AI-powered tools will quickly generate prototypes based on previously optimised designs, which allows faster iteration, testing, and, thus, innovation cycles.
Thanks to efficient AI algorithms, prototypes are created with a higher precision, closely matching the final specifications. This aspect is particularly valuable as it reduces extensive modifications and adjustments during the testing phase.
Feedback loop. AI facilitates a continuous feedback loop in which data from each prototype iteration is analysed to inform the next version, leading to exceptional improvements in design and performance with each cycle.

It is clear that AI is invaluable here; not only does it accelerate innovation, but it also delivers products that are perfected to meet the highest standards.

Staying Ahead of the Curve: Predictive Maintenance and Lifecycle Management

One final aspect we want to discuss regards predictive maintenance and lifecycle management. AI brings priceless benefits here as well, enhancing these areas with its handy insights and automated solutions.

For instance, AI systems ensure a useful proactive approach; they are programmed to effectively and accurately monitor spring performance in real-time and predict when maintenance is required to anticipate potential failures. This way, any critical issue is addressed and resolved before it escalates to something more serious, reducing the risk of sudden breakdowns and extending the spring’s lifespan.

Instead, for lifecycle analysis, AI will follow a spring from design to end-of-life to understand wear patterns, failure points, and optimal maintenance schedules. This will reduce downtime and optimise maintenance costs, leading to more reliable operations and better resource management.

Elevate Your Engineering with European Springs

At European Springs, we stay abreast of the latest AI innovations, employing modern techniques and procedures to keep up with industry advancements and take full advantage of the benefits offered by AI technology. Our commitment to the latest technology ensures that we deliver superior spring design and prototyping services, improving efficiency, accuracy, and reliability. Contact us to learn more about how our successful solutions will elevate your engineering projects, and don’t forget to browse our extensive spring catalogue for all your spring needs.

Springs are integral to a wide range of applications across an equally large number of industries, from automotive to power to transport and defence. These small yet essential components are critical to key aspects such as absorbing shock, ensuring constant force, and maintaining structural integrity and operational efficiency in industrial machinery. It is then crucial to identify potential issues in the early stages to prevent serious consequences such as equipment damage and setbacks.

But what are the most common spring issues? In this blog, drawing upon our extensive experience as spring manufacturers, we will identify and explore the most frequent ones and their consequences so you can take proactive measures to keep your equipment running smoothly and with longer lifecycles.

Common Spring Issues and How to Identify Them

The various spring designs are made to endure specific forces and harsh environmental environments, which, of course, over time will lead to different issues. The most common include deformation, loss of load, and noise, which derive from factors such as excessive stress, improper use, wear and tear, misalignment, and improper installation.

It is incredibly important that these problems are identified early on, not only to prevent potential dangerous failures but also to guarantee the springs’ reliability, safety, and extended lifespan. Regular inspections and maintenance are then essential to ensure the performance of these components remains excellent. Let’s look into these issues in more detail.

Spring Deformation

Deformation is one of the earliest signs of potential failure and includes the bending, twisting, or warping of a spring’s original shape. It is mainly due to spring failure or improper installation. For instance, compression springs that appear curved or misaligned have likely been deformed; measuring their dimensions and comparing them with the original specifications can help detect these changes.

Spring Loss of Load

Loss of load is another critical indicator of spring failure and happens when a spring can no longer exert the required force. It can result from material fatigue, overloading beyond the spring’s limits, or corrosion, among other factors. For instance, if tension springs cannot maintain their supposed tension or sag under a reduced load, they may have lost their load-bearing capability. Conducting load tests can help confirm this issue.

Spring Noise

Unusual noise, such as squeaking, popping, or grinding, is another frequent sign of spring failure. If you hear these noises, it could indicate that the spring is misaligned, improperly installed, or damaged, as they are often caused by friction with other components or excessive vibration. For example, if your torsion springs produce creaking sounds during operation, it could be due to friction or misalignment. Lubricating the spring and its contact points can sometimes resolve the issue if the noise is due to friction.

Fatigue, Overloading, and Corrosion: The Three Spring Failure Modes

Fatigue, overloading, and corrosion are the three main spring failure modes. Knowing them is vital, as it allows experienced spring manufacturers like us to take the right steps, including accurate inspections and thorough cleaning, to eliminate any potential risks. Let’s explore each mode and understand their impact.

Spring Fatigue

Fatigue mostly affects spring types that undergo repetitive loading and unloading cycles. Over time, this repeated stress can cause micro-cracks to form within the material, eventually leading to complete failure. The spring must be used within its specified limits to prevent fatigue and avoid excessive cycling, and it must be regularly inspected for any signs of wear and tear.

Spring Overloading

Overloading occurs when a spring is subjected to loads beyond its designed capacity. Unexpected external forces can lead to overloading, causing permanent damage or failure. Taking a proactive approach to load management is key to avoiding failures and maintaining the reliability of spring applications.

Spring Corrosion

Corrosion is frequent in those springs exposed to harsh environments where moisture, chemicals, and salts can cause their material to deteriorate over time, leading to premature failure. Signs of corrosion include rust, pitting, and discolouration of the spring’s surface. To prevent corrosion, you should employ plating solutions to improve corrosion resistance in springs or materials such as stainless steel.

The Consequences of Spring Failure

Spring failures can have a significant impact on both productivity and the bottom line. Let’s look into the main consequences:

Machine downtime. When a spring fails, it can lead to unplanned downtime in your machines or equipment. This will disrupt production schedules, cause delays, and affect overall efficiency. Time lost during repairs or spring replacement can result in substantial financial losses.
Safety hazards. Failed springs can pose serious safety hazards, endangering both machine workers. In safety-critical systems, such as automotive suspension or braking, spring failures can compromise the overall functionality, putting lives at risk.
Increased costs. Spring malfunctions not only lead to costly repairs but also additional expenses, including investigation and diagnosis of the root causes of the spring failure and extra expenses related to any damages caused by the failure.

Only by addressing common spring issues in their early stages can these consequences be avoided, ensuring optimal productivity and efficiency.

Choose European Springs for Spring Excellence and Reliability

At European Springs, we are dedicated to providing high-quality spring manufacturing services, leveraging the expert knowledge our engineers have developed to tackle and resolve spring failure successfully. In our spring catalogue, we offer a wide range of products crafted with precision and reliability tailored to meet the most diverse needs and projects. Our commitment to quality and personalised support means we are always ready to assist you by addressing any questions or specific requirements. Contact us today to guarantee your spring systems the best longevity and precision!

Springs are invaluable components that, with their many designs, materials, and applications, significantly contribute to an incredibly varied number of industries, and earthquake engineering is no exception. Highly seismic regions like Japan, for instance, require clever, innovative, and flexible solutions to contain serious damage to buildings, infrastructure, and communities as much as possible and avoid both human and economic losses.

Thanks to their capability to absorb and dissipate energy, springs have proven to be real game changers in seismic engineering, and in this blog, we will see why. Drawing upon our extensive knowledge as spring manufacturers, we will delve into effective solutions in several key areas of this fascinating branch of engineering, highlighting how spring technologies help make buildings and urban infrastructures safer and more resilient.

Base Isolation Systems to Improve Earthquake Resilience

Seismic engineering resorts to effective spring applications to build solid base isolation systems, which are specifically designed to decouple a building or structure from ground motion during an earthquake. Here, different spring types are often combined with other materials, such as elastomers, to create hybrid isolators that provide both vertical and horizontal flexibility. By absorbing the kinetic energy generated by seismic activity, springs convert it into heat and reduce the impact of the force that reaches the structure above. We could then say that, basically, base isolators act as a buffer between the structure and its foundation, allowing the urban structures to move independently of the ground and its vibrations.

The effectiveness of base isolation systems has proved largely successful. Despite its complexity, the method has been implemented in various high-risk seismic zones around the world, including Japan and California, to protect new buildings and bridges from severe damage and make them safer.

Reducing Vibrations and Protecting Structures with Seismic Dampers

Spring technology is also a pillar of seismic dampers, those devices that in earthquake engineering are meant to dissipate the abrupt energy of seismic waves to reduce the amplitude of vibrations and prevent structural failure. Due to their enormous benefits, these innovative dampers are installed within structures requiring support in withstanding seismic forces, such as buildings and bridges.

There are different spring-based damper types, the most common of which are:

Viscous dampers contain coil tension springs that work in conjunction with a viscous fluid to absorb and dissipate energy.
Friction dampers use leaf springs to maintain constant pressure on friction surfaces, converting kinetic energy into heat.
Tuned mass dampers use coil spring mechanisms to counteract the vibrations of a structure, reducing its powerful oscillations.

By successfully employing seismic dampers, the impact of earthquake activity is substantially lowered, helping regions exposed to high risks to contain damage and losses.

Strategies for Retrofitting Existing Structures Against Earthquakes

Another important aspect of seismic engineering is retrofitting existing structures to improve their resilience should an earthquake strike occur.

Unfortunately, most older or historical buildings, bridges, and critical infrastructure, like those found in several towns in Italy, were not designed with seismic standards in mind, and they are extremely vulnerable to earthquake damage. Luckily, with technological and architectural advancements, the integration of spring-based systems has emerged as a great solution for retrofitting these structures, enabling them to effectively withstand seismic activity, often eliminating partial or total reconstruction.

Base isolators and the seismic dampers already discussed represent the most common retrofit solutions in existing buildings. The first ones, when installed at the foundation level, reduce the seismic loads transmitted to the building and preserve its structural integrity. The second ones, instead, enhance the building’s energy dissipation capacity, reducing the risk of collapse during an earthquake.

Withstanding Seismic Events with Resilient Infrastructure

The first step to making buildings seismic-proof is designing their resilient infrastructure to improve the safety and functionality of communities around them. Here, springs are vital as they provide engineers with flexible, energy-absorbing solutions to strengthen bridges, highways, pipelines, and utility networks.

For instance, bridges are incredibly vulnerable to seismic forces due to their shapes, long spans, and heavy loads. Employing spring-based isolation bearings in bridge design then represents an excellent way to help absorb seismic energy, reducing the risk of collapse. At the same time, pipelines are equipped with spring-loaded joints that allow for fluent movement and additional flexibility, preventing ruptures and maintaining their integrity to avoid dangerous gas, petrol, or water leaks.

As we can see, springs might be overlooked at times, but by integrating them into the design of urban infrastructure, engineers can successfully create systems that withstand seismic events and recover quickly.

Advancements in Seismic Engineering Technologies

The seismic branch of engineering is surely fascinating and complex, but it is also in constant evolution. Through ongoing research, advancement, new technologies, methodologies, and materials, it aims to enhance earthquake protection as much as possible, using springs as key components.

Recent advancements, for example, include the development of smart spring systems that are easily adaptable to suit varying seismic conditions. These systems are characterised by extreme dynamism as they use advanced materials and sensors to monitor and respond to seismic activity in real-time, providing effective protection promptly. Additionally, energy harvesting and damping control technologies are creating more efficient and responsive solutions, further improved by composite materials to produce lighter, stronger springs that offer superior performance in seismic applications.

Make Urban Structures Safer with European Springs

If you are an engineer specialising in seismic engineering and are working towards making urban structures safer and more resilient for all, do not hesitate to turn to European Springs for premium quality springs that will take your projects to a whole new level.

As leading spring suppliers, we strive to offer excellence and precision in every spring we manufacture, delivering our clients the ultimate customer experience. Browse our spring catalogue and contact us for further assistance if you have specific questions about our services or products.

Springs are key components found in an enormous amount of machinery, vehicles, and countless other complex systems across various industries, some of which are extremely challenging due to harsh environments. Here, corrosion emerges as a formidable enemy, compromising materials, lifespans, and overall safety of the equipment springs support due to significant deterioration.

To avoid this and maintain structural integrity and operational reliability, plating surface treatments are the most effective solutions, as they create a barrier against those factors that cause corrosion. In this blog, we will use our knowledge and experience as spring manufacturers to explore the various types of plating solutions available, focusing on their characteristics, invaluable benefits, and overall effectiveness in resisting corrosion.

Zinc Plating: The Secret Behind Long-Lasting Springs

Zinc plating is one of the most widely used methods for improving the corrosion resistance of springs. It consists of coating the component with a layer of zinc, which acts as a sacrificial anode. As zinc is more reactive than the steel typically used in spring manufacturing, it corrodes first, protecting the underlying material. This action is particularly relevant in lifespan extension, especially in harsh environments – such as the marine sector – where they are exposed to moisture and other corrosive elements (in this case, salt).

In terms of application, zinc plating is relatively straightforward and cost-effective, which makes it a popular choice in many industries. In the power sector, for example, where equipment is often battered by challenging outdoor conditions, zinc-plated springs resist rust and degradation successfully.

For durability, zinc coatings can be enhanced with additional treatments, such as chromate conversion coatings, for an extra layer of protection. Additionally, the bright, shiny finish obtained makes zinc-coated springs particularly desirable in visible applications.

Nickel Plating to Enhance Strength and Shine

Whether torsion springs, compression springs, or tension springs, nickel plating involves adding a supplementary layer of nickel onto their surface through an electroplating process. Thanks to nickel’s inherent resistance to oxidation, the final spring benefits from an excellent protective barrier against corrosion alongside increased hardness and improved wear resistance, which contributes to its enhanced longevity and performance.

Nickel plating is particularly valuable as a protective method due to its ability to withstand extreme temperatures and harsh environments. A fitting example could be springs in hydroelectric power, including turbines, generators, and other critical equipment, which often operate under severe conditions. Thanks to nickel plating, they maintain their structural integrity and functionality over extended periods. The resulting smooth, uniform finish offered by this process also reduces friction and wear, a vital aspect of ensuring the efficiency of moving parts within complex machinery.

Chrome Plating for Reflective Strength

Chrome plating is renowned for its outstanding hardness and shiny aesthetic appeal. The coating layer provided by this highly demanded material improves the durability and appearance of any spring type. The plating process sees the application of a thin layer of chromium to the surface of the component, resulting in an exceptionally reflective and tough coating. Its ability to resist corrosion, oxidation, and wear makes it a standout choice for springs heavily exposed to extremely challenging environments.

By benefitting from the robust protection offered by chrome plating, springs used in hydraulic valve systems or other high-stress applications easily exhibit unmatched mechanical strength and corrosion resistance. The most distinctive feature of this coating is that it withstands harsh chemicals and high temperatures, offering an incredibly reliable performance in demanding conditions. Last but not least, the smooth surface of chrome-plated springs reduces friction and wear, improving the overall efficiency and lifespan of the equipment which uses them.

Electroless Nickel: Precision Coating for Perfect Springs

In industries where springs operate in corrosive and high-temperature environments, electroless nickel plating is particularly advantageous.

This unique plating technique offers extraordinary uniform coverage and excellent corrosion resistance. Unlike traditional electroplating, which relies on an electric current, electroless nickel plating involves a chemical reaction, where a layer of nickel-phosphorus alloy is deposited onto the spring surface. This guarantees an even coating, even on complex geometries and hard-to-reach areas, providing complete protection.

The phosphorus contained in the coating reinforces the components’ corrosion resistance, and, especially in custom spring designs, our team will tailor it to meet specific environmental challenges, especially in custom springs. Electroless nickel plating also provides superior hardness and wear resistance, which is particularly valuable for springs exposed to repeated mechanical stress. All in all, this effective plating solution is ideal for applications such as electrical connectors, circuit breakers, and other components where precise performance is non-negotiable.

Green and Tough: The Benefits of Organic Coatings

Finally, they may be less frequent, but organic coatings are a fantastic, versatile, and extremely effective solution for protecting springs against corrosion damage. They can be designed to offer specific functional properties, such as low friction or increased adhesion, extending the utility of springs in diverse uses.

These coatings are typically composed of polymers or other organic compounds, providing a flexible and resilient barrier that can confidently face a wide range of environmental conditions. Unlike metallic coatings, organic coatings can be applied in various thicknesses and formulations to meet specific requirements, meaning they are completely customisable. They often are an obligated choice across various industries in applications where traditional metal coatings might not be suitable. For example, springs in electronic devices, battery systems, and other sensitive equipment benefit from the non-conductive properties of these coatings. It is worth mentioning an additional advantage: spring types featuring organic coatings resist not only moisture and chemicals but also UV radiation, ensuring long-term protection and durability.

Make Your Springs More Resistant with European Springs

As a leading spring supplier at European Springs, we excel in providing advanced plating solutions for your springs and offer a variety of surface treatments to meet the needs of diverse industries. These treatments include heat treatment, barrelling, and de-burring, each designed to enhance the performance and durability of our springs.

Our flexible approach ensures that our springs can withstand the toughest environments and deliver the most reliable performance. Browse our spring catalogue or contact us directly to discover how we can help your business achieve more long-lasting solutions.

Author: European Springs Web Team