Technical Foundation
What Is a Wave Washer?
A wave washer is a flat spring formed with a series of waves around its circumference, so that under axial load it deflects and stores spring energy the way a coil spring does, but in a much shorter axial space. They're specified anywhere a design needs to take up end-play, preload a bearing, or absorb thermal expansion without adding stack height — bearing retention, electric motor end caps, and clutch assemblies are common uses.
Wave count and number of turns determine the spring rate and available deflection for a given radial cross-section: more waves in a single turn increase the spring rate but reduce deflection per wave, while multi-turn (nested) wave springs stack several waved rings to reach higher forces in the same bore. Material and finish are chosen for the operating temperature and corrosion environment, since a washer under continuous spring load is more sensitive to stress relaxation than a flat washer carrying no working deflection.
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| Spec | What It Means | Why It Matters |
|---|---|---|
| Wave Count | Number of waves per turn (2, 3, 4, 6...) | Sets spring rate — more waves means higher force for the same deflection and radial space |
| Number of Turns | Single-turn vs. multi-turn (nested) wave springs | Multi-turn springs reach higher loads in the same bore by stacking turns axially |
| Inside/Outside Diameter | Bore fit and housing OD | Must match the shaft and bore diameters of the assembly for correct seating |
| Material | 302/17-7PH stainless, carbon spring steel | Stainless resists corrosion and holds spring rate better at elevated temperature |
| Free Height / Deflection | Uncompressed height and working travel | Determines how much end-play or preload the washer can take up before going solid |
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Applications
Where Wave Washers Get Used
Wave washers are specified anywhere axial spring load is needed but stack height is limited.
Bearing Preload & Retention
Taking up axial clearance in ball bearing assemblies to reduce noise and vibration under running load.
Electric Motors & Actuators
Preloading motor shaft bearings and absorbing thermal growth between end caps and the rotor shaft.
Clutch & Brake Assemblies
Applying consistent axial spring force across friction plates in compact clutch and brake packs.
Valve & Pump Assemblies
Maintaining seal and seat contact force as components wear or thermally expand in service.
Consumer & Appliance Products
Low-cost axial spring loading in switches, connectors and small motor assemblies with tight space budgets.
General Machine Design
Compact axial spring loading anywhere a coil spring's stack height won't fit the design envelope.
FAQ
Wave Washers Questions, Answered
How is a wave washer different from a Belleville (disc spring) washer?
A wave washer is flat with waves formed around its circumference and generally gives a lower spring rate and more deflection per unit force than a Belleville washer, which is a coned disc that deflects flat under load. Belleville washers typically handle higher loads in a smaller deflection range; wave washers are chosen when a lighter, more linear spring force over a longer travel is needed in a compact axial space.
What's the difference between single-turn and multi-turn (nested) wave springs?
A single-turn wave washer is one continuous waved ring. A multi-turn (nested) wave spring stacks several waved turns on top of each other within the same bore, multiplying the available spring force and travel without increasing diameter — used when a single-turn washer can't generate enough load in the available radial space.
How do I choose the right wave count for my application?
More waves per turn raises the spring rate (more force per unit deflection) but reduces the deflection available per wave, while fewer waves give a softer, longer-travel spring. Choose wave count based on the target load-deflection curve for the assembly — a bearing preload application generally wants a soft, forgiving rate, while a high-force retention application wants a stiffer curve.
What material should I specify for a wave washer under continuous load?
302 or 17-7PH stainless steel is standard where the washer stays under continuous spring load, since these alloys resist stress relaxation (permanent loss of spring force over time) better than plain carbon spring steel, especially at elevated temperature. Carbon steel is acceptable for lower-cost, lower-temperature applications where some relaxation over the product's life is tolerable.
Can a wave washer be substituted with a stack of Belleville washers?
Not directly — the load-deflection behavior differs enough that a design calling out a specific wave washer part number should be matched to an equivalent wave washer, not converted to a Belleville stack, without re-verifying the assembly's preload and travel requirements. ChatMRO can help cross-reference an existing part number to confirm an equivalent.
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