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This work outlines the fatigue failure in a failed helical coiled compression spring of a passenger car used as a commercial vehicle. As a failure investigation case study, the fractured left rear axle suspension spring of the car is thoroughly examined. The fractographic investigations included the visual examination, spectroscopy, microstructure analysis, SEM and micro-hardness testing. The foremost causes of failure have been identified. From the SEM fractograph, microvoid coalescence is observed at the grain boundaries on of the fractured surface which eventually resulted in intergranular dimple rupture. Residual stress is also measured on the fractured surface through two-dimensional (2-D) imaging using a Debye Scherrer ring, with the conclusion that the spring under investigation experiences micro-stress due to the variation of theintergranular spacing resulting from the vibrations induced by overloading, road conditions and prolonged use which eventually results in a rupturing of the compression spring.

Experimental investigation of fatigue failure in an ASTM A401 compression spring of a passenger car