In the metal forging industry, craftsmen often compare the qualities of the two most commonly used metal alloys – wrought iron and cast iron. The conversation even goes as far as pitting one against the other in terms of which one is better.
If you’ve been wondering which material is better for your home renovation project we’re here to help out. We’ll take a look at the difference between wrought and cast iron, compare the two metals’ properties, and look at the advantages of each. We’ll also look at where both iron alloys find their application.
Let’s dive right into it.
Wrought iron derives its name from the archaic past participle of the word “to work”, it literally means worked iron. It was named so, thanks to its incredible flexibility, ideal for creating exquisite ornamentations and twisted designs.
The metal is malleable and stringy, made from semi-infused fairly pure iron beads and iron slag (thanks to which the metal has a grainy texture). Wrought iron contains no more than 0.1% carbon and 1 to 2% slag.
The material is durable, corrosion-resistant, and relatively easily forged through welding. It’s highly refined with up to 99% of its mass being iron. The remaining amount of slag adds to its shock and vibration resistance and eases its processing by blacksmiths.
Cast iron is an iron alloy that is formed by reducing iron ore in a blasting furnace. Once the iron ore is melted in the furnace it gets poured into crude ingots, named pigs. This is the form in which the cast iron is usually stored.
Once needed the cast iron pigs are remelted along with metal scrap and alloying elements in cupola furnaces and recast in molds shaped in the desired product.
Cast iron contains more than 2% carbon, along with different amounts of manganese, silicon, sulfur, and phosphorus. Depending on the quantity of each additional element (impurities) the cast iron exhibits different properties and falls under a distinct type.
Among the types of cast iron are cast iron with varying alloying elements (most predominant of which is silicon), gray cast iron, white cast iron, malleable cast iron, and ductile cast iron.
Though both are derived from iron – wrought iron and cast iron are formed differently and exhibit their own distinct physical properties.
How can one tell wrought iron and cast iron apart?
The easiest way to tell them apart is based on the way they are worked with. Wrought iron is heated and then worked on with tools, while cast iron is melted, poured into molds, and allowed to solidify. The different ways these metals are produced (which we pointed out in the previous sections), also influence the wrought iron and cast iron’s strengths and weaknesses.
So let’s look at the two metal alloys’ properties that give them their advantages.
Compared to wrought iron, cast iron is hard but brittle and very difficult for molding.
It generally doesn’t have much allowance for bending, stretching, or hammering into shape. It’s also harder to cut.
However cast iron has excellent compression strength – perfect for construction projects. It requires little machining (finishing processes), and it’s highly wear-resistant. The material is highly available and comes at a lower cost.
Wrought iron, on the other hand, is made to be manually crafted. It’s very bendable, flexible, and has high fatigue resistance (it can undergo large amounts of deformation before failing).
The material, however, cannot be hardened through heating or quenching. It’s a labor-intensive metal and is more expensive than cast iron.
Both cast iron and wrought iron are arguably two of the most important materials in human history. Thanks to both, some of the most iconic historic monuments have been erected and still stand today.
The famous Eiffel Tower was constructed thanks to 7,300 tons of wrought iron. And about 4,100 tones of cast iron were used for the dome of Capitol Hill in Washington D.C.
Along with their application in historic buildings, wrought iron and cast iron find a wide range of applications in everyday items and industrial elements.
Back in the day, for instance, wrought iron was frequently used for nails, nuts, bolts, rails, pipes, and even horseshoes.
Today wrought iron is prominently found in decorative interior and exterior pieces like doors, railings, gates, fences, pergolas, and more. Wrought iron is also common in patios and other outdoor furniture.
The use of cast iron depends on the type of cast iron. Gray cast iron is the most commonly utilized cast iron. It’s found in applications where high stiffness, vibration damping, high heat, and thermal conductivity are needed. That’s why the material is in high demand for the production of internal combustion engine cylinder boxes, gearboxes, disk brakes, rotors, and other automotive parts.
Gray cast iron is also a common cookware material with some of the most lasting and praised pots and pans made from this alloy.
The white cast iron is praised for its abrasion resistance and finds applications in elements like extrusion nozzles, cement mixers, crushers, pump impellers, pipe fittings, and flanges.
Malleable cast iron, thanks to its high tensile strength and flexibility, is used in electrical fittings and equipment, pipe fittings, hand tools, washers, farm equipment, and mining hardware.
Ductile cast iron is widely used in water piping and sewage installations, due to its superior ductility. It also finds applications in vehicle gears and suspension components, housings for wind turbines, and hydraulic parts.
Seeing the difference between the two iron alloys it’s clear that cast iron is more suitable for industrial applications with fewer home applications like piping or home kitchenware.
If you’re looking for those design pieces that will add to your home’s security and functionality at the same time, wrought iron will be a more fit choice. Wrought iron’s malleability is great for a range of interior and exterior projects from simple fireplace doors to sophisticated railing systems.
When it comes to home design and renovation we’re often faced with multiple options and choices. And choosing the best materials requires time in investigating what materials are best for your needs. This whole process can easily get overwhelming.
So to help you out we’ve gathered some fundamental information on what wrought iron and cast iron are; the differences between them; their best applications; the materials’ advantages and disadvantages.
For further consultation on the wide variety of design applications of wrought iron, you can get in touch with Cacciola Iron Works.
Anthony Cacciola’s team has been serving the New York and New Jersey area for almost 40 years, with multiple wrought iron projects adorning the homes of our repeat customers.
Get in touch today!
Iron and steel, often referred to interchangeably, are distinct metals with unique characteristics and applications. From malleable pure iron to robust wear resistant steel, the world of metal alloys is diverse and includes many differences when it comes to their production processes and applications.
Different metal alloys are not just commodities but fundamental components of our daily lives. Each one serves a distinct purpose, shaping industries and innovations. Iron ore is the base element to make all grades of iron and steels, and is also an essential mineral which helps make hemoglobin in the human body.
Let’s explore the different types of iron and wear resistant steel available today, as well as their properties and functions.
Pure iron, with its silvery-white appearance and relative softness, is a central element in the world of metallurgy. Its pliability allows for easy manipulation, with the ability to be cut with a knife, hammered into sheets, and drawn into wire.
Today, pure iron is used in specific applications such as magnets, electrical components, and specialized machinery due to its excellent conductivity and magnetic properties. However, it is vulnerable to corrosion, as it readily combines with oxygen. And despite its versatility, the soft nature of pure iron can limit its practical applications.
The journey from iron ore to steel involves a key halfway stage known as pig iron. Produced through the heating and melting of iron ore in a blast furnace, this process includes the addition of coke (coal) and limestone. The coke’s role is important, absorbing most of the oxygen from the iron ore and resulting in the formation of chunky blocks colloquially known as “pigs.” These pigs, consisting of 90 to 95% iron and 3 to 5% carbon, represent a purer form of liquid iron with enhanced hardness compared to pure iron.
Pig iron is primarily used as a key raw material in the production of steel, serving as a foundational component in various industrial applications such as automotive parts, construction materials, machinery, and pipelines.
The transformation of liquid iron or pig iron into cast iron occurs through the casting process, where the molten metal is poured into molds to create various parts, such as cast iron water pipes, cookware, and certain structural components. The high carbon content (3 to 5%) renders cast iron exceptionally hard but also brittle, limiting its utility in shaping and machining applications.
Wrought iron is a more malleable and rust-resistant variant of iron. By introducing slag to liquid iron, the carbon content is reduced, resulting in a softer and more shapeable material. While wrought iron boasts historical significance, its production has waned in modern times, with steel emerging as the predominant choice in contemporary applications. Today, wrought iron is not as common but still used for decorative purposes, such as ornamental gates, railings, and artistic elements.
Known for its versatility, steel is an alloy that blends iron with various elements such as carbon, manganese, nickel, and copper. The addition of less than 2% carbon, combined with specific alloying elements and heat treatment, yields an extensive array of steel grades. The nomenclature, ranging from low and high carbon steel to manganese steel, alloy steel, tool steel, wear resistant steel, and stainless steel, reflects the varying compositions and diverse properties within the broader category of steel.
Steel is widely used today in various industries, including construction, automotive manufacturing, infrastructure development, and consumer goods production, due to its exceptional strength, durability, and versatility.
Wear resistant steel is a specialized type of steel designed to withstand abrasion, impact, and other forms of wear and tear, making it particularly well-suited for applications in challenging environments.
Unlike traditional steel, wear resistant steel undergoes a unique hardening process that enhances its durability and resistance to surface wear. This steel variant is often used in industries where machinery and equipment are subjected to harsh conditions, such as mining, construction, manufacturing, and material handling.
The key advantage of wear resistant steel lies in its ability to maintain structural integrity, providing extended service life and minimizing the need for frequent replacements, ultimately reducing maintenance costs for various industrial applications.
Within the wide range of steel, wear resistant steel plays a key role in applications demanding durability and longevity. Titus Steel, a renowned distributor and fabricator, specializes in high-alloy “work-hardening steels” like TITUS Manganese, ENDURA, and ENDURA Dual. These steels possess a unique characteristic – their hardness increases upon impact, making them ideal for scenarios where wear resistance is paramount.
Titus Steel’s commitment to providing top-notch wear resistant steels is underlined by exclusive focus on high-alloy, work-hardening variants. These steels, born from iron ore, demonstrate unparalleled resilience. Hit them with a hammer, and they get harder; hit them again, and they further intensify in hardness. This remarkable feature has positioned Titus Steel as a leader in the world of wear resistant steel.
For industries and applications requiring wear resistant steel, Titus Steel stands as a reliable partner. Our expertise lies not only in distribution but also in fabricating products tailored to specific needs.
By understanding the unique properties of TITUS Manganese, ENDURA, and ENDURA Dual, your business can make informed decisions on the ideal wear resistant steel for your particular requirements.
Contact us today for further information about our products and to receive a personalized quote on wear resistant steels tailored to your specific needs.