Conical Spring Washer

Product Overview

Conical spring washers maintain continuous axial pre-load in bolted assemblies subject to heavy vibration and thermal fluctuation. Unlike flat washers, the conical geometry stores elastic energy as deflection occurs, compensating for bolt relaxation, creep, and differential thermal expansion.

Parameter Category	Standard Metric Range	Standard Inch Range
Size Range (ID)	M3 to M100	#4 to 4 inches
Material Thickness (t)	0.2 mm to 12.0 mm	0.008 in to 0.472 in
Load Capacity	100 N to 250,000 N (at flat position)	Per DIN 2093 / Custom Spec
Tolerance Class	DIN 2093 Group 1, 2, 3	ASME B18.21.1

Product Types & Configurations

DIN 2093 Belleville Washers:

Precision-stamped components engineered for high load capacity in restricted axial spaces; stackable in parallel or series arrangements to modify load-deflection profiles.

DIN 6796 Heavy-Duty Washers:

Designed specifically for high-stress bolted joints in structural and automotive applications to resist immediate settling and vibration loosening.

Wedge-Lock & Multi-Stack Assemblies:

Paired configurations utilized in power transmission equipment to multiply total deflection stroke while sustaining constant clamp load.

Custom Stamped Profiles:

Non-standard outer/inner diameters, slotted geometries, and variable thickness gradients manufactured directly from customer CAD data.

Key Features

High Energy Density:

Concentrates maximum load potential within a minimal footprint.

Dynamic Shock Absorption:

Continuous spring deflection absorbs transverse vibration and impact loads.

Thermal Drift Compensation:

Accommodates differential expansion rates between steel fasteners and aluminum or copper housings.

Strict Load Predictability:

Governed by precise mathematical deflection curves per DIN 2093 specifications.

Materials & Surface Options

C67S, C70S, and 50CrV4 (AISI 6150) delivering high fatigue strength and elasticity after thermal processing.

X10CrNi18-8 (AISI 301) and X5CrNiMo17-12-2 (AISI 316) for chemical resistance and cryogenic or elevated-temperature service.

Inconel 718, Nimonic 90, and Beryllium Copper for extreme heat environments (greater than 500 degrees C) or non-magnetic operations.

Mechanical Zinc Plating, Zinc Flake Coatings (Geomet/Dacromet per ISO 10683 for 720 plus hours salt spray protection), Phosphating, and Passivation.

Applications

Power Distribution:

Copper busbar connections in switchgear and transformers where thermal cycling induces joint creep.

Heavy Machinery:

Flange connections in hydraulic pumps, industrial gearboxes, and earthmoving equipment.

Energy Infrastructure:

Wind turbine tower flange bolts and solar tracking pivot mechanisms.

Automotive:

Transmission housings, brake system assemblies, and exhaust manifold joints.

Manufacturing & Quality Control

01.

Stamping & Blanking:

Progressive die stamping executed across 45T to 400T mechanical and hydraulic presses, maintaining burr-free edges, clean shear planes, and tight profile tolerances.

02.

Heat Treatment:

Continuous belt furnaces featuring endothermic controlled protective atmospheres to achieve uniform hardness profiles (42 to 52 HRC for spring steels) while minimizing surface decarburization and distortion.

03.

Inspection & Testing:

100 percent automated optical sorting for dimensional conformance; destructive load-deflection verification performed on computerized compression test rigs adhering strictly to DIN 2093 evaluation guidelines.

04.

Traceability:

Comprehensive lot control mechanisms linking every production batch to raw material heat numbers, supported by Material Test Reports (MTR) supplied per EN 10204 3.1 standards.

Customization & OEM

Prototyping Support:

Rapid sample fabrication via precision laser cutting and short-run tooling options completed within 7 to 10 business days for immediate design validation.

Engineering Review:

Systematic calculation of optimal thickness, stack height, and parallel versus series configurations based on user-supplied assembly parameters and load targets.

Packaging Solutions:

Heavy-duty VCI anti-corrosion poly bagging, robust industrial export cartons, and automated barcoded labeling structured for direct integration into automated tier-1 assembly lines.

FAQ

Q: How do I choose between a parallel stack and a series stack of conical washers?

A: Parallel stacking (washers oriented in the same direction) multiplies the total load capacity while maintaining the deflection range of a single washer. Series stacking (washers alternating directions) multiplies the total deflection stroke while keeping the load capacity equal to a single washer. Selection depends on your specific bolt pre-load requirements and anticipated thermal movement.

Q: What is the risk of hydrogen embrittlement in high-strength spring steel washers?

A: High-strength carbon spring steels exceeding 40 HRC are vulnerable to hydrogen absorption during acid cleaning and electroplating. To eliminate this failure mode, our manufacturing line utilizes mechanical plating or baking-certified zinc flake coatings (such as Geomet) applied within 4 hours post-plating to drive out trapped hydrogen.

Q: Can conical spring washers be reused after joint disassembly?

A: Reusability depends on whether the washer was deflected beyond its elastic limit during initial tightening. If operated within the recommended deflection range (15 percent to 75 percent of total deflection height minus thickness), permanent set is negligible, allowing nominal clamp load retention upon re-assembly. Visual inspection for flattening cracks or wear is mandatory prior to reuse.

Q: What documentation is provided with bulk shipments?

A: Every delivery includes a Certificate of Analysis (CoA) reporting actual lot test values for hardness, dimensions, and load verification at flat position, alongside raw material mill test reports (MTR) traceable to the original heat number.

Q: How does thermal expansion affect joint performance in aluminum housings?

A: Aluminum exhibits a significantly higher coefficient of thermal expansion than steel fasteners. As operating temperatures rise, the aluminum housing expands faster than the bolt, opening the joint gap. Conical spring washers compensate by extending their deflection stroke, sustaining the minimum required clamping pressure without unseating the fastener.

Q: What are your standard lead times for custom-engineered dimensions?

A: Standard catalog inventory ships within 3 to 5 business days. Non-standard geometries requiring dedicated progressive stamping dies or custom alloy procurement typically require 3 to 4 weeks for tooling completion, sample validation, and volume production.

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