Alright, I'll weigh in on this as I am a mechanical
engineer, and I've also had this very discussion with a friend of mine who is a metallurgist.
In general, a
spring that is compressed
within its fatigue limits does not experience wear. Instead, it is the cyclical act of compressing/expanding a
spring that creates fatigue. Fatigue is caused by cycles, which in the case of mag springs means loading and unloading. Leaving a
PROPERLY DESIGNED AND WELL MADE spring compressed
WITHIN ITS DESIGN PARAMETERS will not hurt it at all. Not even over YEARS.
Once again,
only load/unload cycles count on the fatigue scale.
Expect a quality mag
spring to soak up AT LEAST a thousand cycles. If you have enough ammo to be worrying about that many cycles, buy a spare mag or two..
You also need to make sure you do not overstress a
spring. NEVER try to shove "extra rounds" into a mag. If it says it is a 15 rounder then only put in 15, not 16 (even if you are physically able to do so). Fatigue is a 3-stage failure mechanism and if you overstress a part enough you get to skip the first phase (pre-crack initiation) completely.
There are really three stress points of interest when discussing steel: Ultimate Tensile Strength, Yield Tensile Strength ("elastic limit"), and fatigue limit.
Here is an example: 4140 Cr-Mo low-alloy steel is very versatile. When quenched and tempered to about 180,000 psi Ultimate Tensile Strength (UTS) or roughly HRC 40 it has a YTS of about 120,000 psi and a fatigue limit of about 80,000 psi. So what do these numbers mean?
- If you load the 4140 to more than 180,000 psi in tension it will break.
- If you load it to between 120,000 and 180,000 psi in tension and then unload it you will have some deformation (yielding) that will not recover. Higher load means more deformation. The steel will not take many loadings like this. Think of bending a paper clip when you think of something stressed beyond its elastic limit.
- If you load it to less than 120,000 but more than 80,000 psi in tension and then unload it, it will perfectly recover its pre-load dimensions until after a certain number of cycles, whereupon it will break due to fatigue.
- If you load it to less than 80,000 psi and then unload it you could do this for 900 trillion (or more) cycles and it won't hurt the steel one bit.
So, if you have a high-cycle design part, like those found in internal combustion engines, you NEED to design in a stress range BELOW the fatigue limit. If you expect your part to last for 100 million or fewer cycles then you can design somewhere in between the fatigue limit and the YTS. But even a low-cycle design for fatigue will consider 10,000 cycles. One way parts, like those on missiles, can be designed in a completely different manner since they only make one go of it.
That said - I have had cheap mags break springs in just a few cycles. For self-defense I would carry only factory mags if I were you. Let the cheapies be for relaxed range time where a malfunction can't kill you.
Also the statement about only cycling hurting springs must be qualified with the following conditions:
1 - That they are good quality springs made by a reputable manufacturer
2 - That they are used within their design parameters
3 - That they are not subject to any unusually aggressive environment while stressed