So you think you know a lot about springmaking! Well, try our Gold Star Springmaking Quiz and we'll see. Not for novices, our quiz was compiled from questions contributed by Dan Ault, Peterson Spring; Robert A. Bell, contributing editor to Springs; Loren Godfrey, Associated Spring; Edward J. Hamilton, Winamac Coil Spring Inc.; Michael Limb, Peterson American; Wesley E. Nichols, Spring Specialists Corp.; Alex Rankin, Vulcan Spring & Manufacturing Co.; James J. Skelskey Jr., Industrial Components Division Inc.; Gary Spanos, Connor Spring & Manufacturing Co.; John Stevens, Amstek Metal; Melvyn J. Wallbank, P.J. Wallbank Springs Inc.; and Kenneth R. West.

For each question below, click on the circle next to the correct answer. When you are finished with the test, push the 'Score my test' button at the bottom of the page. Good luck!

Question #1
The load of a constant force spring equally stressed varies with the thickness

A. Directly
B. Squared
C. Cubed

Question #2
General load tolerances of ± 10% may be utilized when specifying designs for most types of flat spring applications

A. True
B. False

Question #3
In setting up an extension spring of type 302 stainless steel, the hooks are positioned slightly less than in line so that they will be in line after stress relief.

A. True
B. False

Question #4
What is the maximum amount of initial tension that can be created in a hot-wound spring made from 0.750 alloy steel with an index of 7.0?

A. None
B. 75% tensile strength
C. 25 percent tensile strength

Question #5
When extension springs are fabricated on coiling machines, the load causing the coils to remain tightly in contact with each other is called "initial tension." The amount of this load is almost wholly dependent upon the spring index (i.e. the mean coil diameter divided by the wire diameter), but it will be different if the spring is produced by a torsion spring coiler or by an automatic compression spring coiler. Can you predict the amount of initial tension typically produced on a torsion coiler as compared with an automatic coiler using two springs of the same index? The "rule of thumb" percentage is:

A. 50%
B. 70%
C. 100%

Question #6
Which wire characteristic is most important for uniform spring coiling?

A. Consistent tensile strength
B. Ovality and size tolerance
C. Uniform lubricant and coating

Question #7
Stainless steel springs have been commercially shot peened using the cost-effective steel shot. On their return from the shot peen company, the springs should be:

A. Inspected, counted and shipped to the customer
B. Stress relieved at a maximum temperature of 450°F, inspected, counted and shipped to the customer
C. Passivated, stress relieved at maximum temperature of 450°F, inspected, counted and shipped to the customer.

Question #8
One of the side benefits of 302 stainless steel (ASTMA313) is that it is nonmagnetic.

A. True
B. False

Question #9
Reducing the index and/or active coils per inch will reduce the load tolerance of a helical compression spring.

A. True
B. False

Question #10
The edge condition is of no importance to the fatigue life of a spiral torsion spring.

A. True
B. False

Question #11
Spring design:
OD = 1.125 in.
FL = 10.00 Ref.
Wire diameter = 0.125 Chr. Si.
No. of active coils = 10 Ref.
No. of total coils = 12 Ref.
Rate = 30 lb./in.
Load (1) @ 9.00 in. = 30 lb. ± 3 lb.
Load (2) @ 7.00 in. = 70 lb. ± 7 lb.
What is the defined spring rate?

A. 20 lb./in.
B. 30 lb./in.
C. 35 lb./in.
D. None of the above

Question #12
Using the design given in question 11, the calculated free length is ____. Also, if OD, wire size and the correct number of coils do not vary, the free length tolerance will be ___.

A. Free length = 12.50 in. Free length tolerance = ± 0.160 in.
B. Free length = 11.00 in. Free length tolerance = ± 0.130 in.
C. Free length = 10.50 in. Free length tolerance = ± 0.150 in.

Question #13
The greatest single contributing cause of hook breakage is:

A. Poor quality wire
B. Insufficient stress relief
C. Overstressing
D. Tool marks in the ends
E. Hydrogen embrittlement

Question #14
Unlike helical springs, constant force springs do not take an initial set.

A. True
B. False

Question #15
When flat springs are subjected to high stresses or repetitive cycling, it is important to know the direction of deflection relative to any residual blanking burrs on edges, holes, slots or notches

A. True
B. False

Question #16
A customer reports hook breakage. Stress calculations indicate high but reasonable levels of hook stress. To reduce this hook stress, taper three coils at each end to a smaller diameter.

A. True
B. False

Question #17
The modulus of rigidity (G) for hot-wound springs made from "as rolled" bar is often multiplied by a correction factor to compensate for scaling and/or decarburization. This factor has what effect on G?

A. Increases the value of G by 10%
B. Decreases the value of G by 10%
C. No effect if the spring is preset three times
D. No effect if compensating bar straightener is used

Question #18
A spring is said to be adequately shot peened when, in order to improve the Almen-Arc rise by 10%, it would be necessary to improve the process time by

A. 10%
B. 50%
C. 100%

Question #19
Torsion-straightened stainless steel spring wire has a tensile strength that is (higher, lower or the same) as cold-drawn spring wire in coil?

A. Higher
B. Lower
C. The same

Question #20
Steel springs are sent to a commercial firm to be shot peened. On return, the parts should be:

A. Inspected, counted and shipped to the customer
B. Stress relieved at maximum temperature of 450°F, inspected, counted and shipped to the customer
C. Stress relieved at a maximum temperature of 450°F, inspected, counted, oiled and shipped to the customer

Question #21
The primary advantage of shot peening springs is to

A. Smooth out surface imperfections in the wire
B. Clean and improve surface appearance
C. Introduce beneficial residual stresses to the wire surface

Question #22
Helical compression springs with closed ends will not buckle if the slenderness ratio (FL/D) is less than 4-to-1.

A. True
B. False

Question #23
A power spring is fully wound at 10 turns with 50 in./lb. torque. It is then unwound 2½ turns. What will be the resulting torque?

A. 37½
B. 47½
C. 42½

Question #24
One of the key ingredients to meeting a customer?s JIT requirements is the reduction of setup time or rejections.

A. True
B. False

Question #25
It is not possible to fabricate an extension spring with a variable rate per inch.

A. True
B. False

Question #26
The torque of a constant torque spring equally stressed varies with the thickness

A. Directly
B. Squared
C. Cubed

Question #27
When space is limited, the solid height of a hot-wound spring with closed and ground ends may be further reduced by additional material removal. This can typically reduce the solid height by:

A. 10%
B. 25% of one wire size
C. 50% of one wire size
D. 50 percent of the calculated solid height

Question #28
When ordering oil-tempered wire, it is appropriate to specify Rockwell hardness rather than tensile strength.

A. True
B. False

Question #29
Steel springs are sent to a commercial shot firm to be double shot peened. The parts should be:

A. Stress relieved at a maximum temperature of 450°F between the two shot peen operations and then again after the final shot peen operation.
B. Stress relieved once, after the double shot peen is completed, at maximum temperature of 450°F.

Question #30
Pitch is defined as the spacing between coils of compression springs while in the uncompressed state.

A. True
B. False

Question #31
The maximum deflection is obtained in a power spring when ________ percent of the available space between the case ID and arbor is used.

A. 75%
B. 50%
C. 60%

Question #32
The major cause of variation on the load of a compression spring is the raw material.

A. True
B. False

Question #33
To avoid excessive extension and resulting permanent set, the deflection of an extension spring may be controlled by using End plugs with a cable between them inside of the coils to limit the extension of the part.

A. True
B. False

Question #34
Baking type 301 stainless steel constant force springs at 500°F

A. Decreases the load
B. Increases the load
C. Does not change the load

Question #35
You are making an extension spring with two loads specified. The first load tests strong, and the second load tests weak. To correct this, you should:

A. First reduce the coil diameter and then reduce the initial tension
B. First increase the coil diameter and then reduce the initial tension

Question #36
Steel springs are sent to a commercial shot peen firm to be double shot peened. Under normal conditions, the shot size should be:

A. The same for each shot peen operation
B. Larger for the first shot peen operation than for the second
C. Smaller for the first shot peen operation than for the second

Question #37
Modulus of elasticity is a constant.

A. True
B. False

Question #38
Type 301 stainless steel constant force springs should be passivated after forming.

A. True
B. False