Wrought iron is an iron alloy with a very low carbon content (less than 0.05%) in contrast to that of cast iron (2.1% to 4.5%), or 0.25% for low-carbon "mild" steel. Wrought iron is manufactured by heating and melting high-carbon cast iron in an open charcoal or coke hearth or furnace in a process known as puddling. The high temperatures cause the excess carbon to oxidise, the iron being stirred or puddled during the process in order to achieve this. As the carbon content reduces, the melting point of the iron increases, ultimately to a level which is higher than can be achieved by the hearth, hence the wrought iron is never fully molten and many impurities remain.
The primary advantage of wrought iron over cast iron is its malleability – where cast iron is too brittle to bend or shape without breaking, wrought iron is highly malleable, and much easier to bend.
Wrought iron is a semi-fused mass of iron with fibrous slag inclusions (up to 2% by weight), which give it a wood-like "grain" that is visible when it is etched, rusted, or bent to failure. Wrought iron is tough, malleable, ductile, corrosion resistant, and easily forge welded, but is more difficult to weld electrically.
Before the development of effective methods of steelmaking and the availability of large quantities of steel, wrought iron was the most common form of malleable iron. It was given the name wrought because it was hammered, rolled, or otherwise worked while hot enough to expel molten slag. The modern functional equivalent of wrought iron is mild steel, also called low-carbon steel. Neither wrought iron nor mild steel contain enough carbon to be hardened by heating and quenching.
The properties of wrought iron vary, depending upon the type of iron used and the variability inherent in the relatively crude and labour intensive manufacturing process. It is generally relatively pure iron with a very low carbon content plus a small amount of mostly silicate slag, which forms fibreous or laminar inclusions, caused by the hot rolling process used to form it into long bars or rods. Because these silicate inclusions separate layers of iron and form planes of weakness, wrought iron is anisotropic, its strength varying depending on its orientation. Wrought iron may typically be composed of around 99.4% iron by mass. The presence of slag can be beneficial for blacksmithing operations, such as forge welding, since the silicate inclusions act as a flux and give the material its unique, fibrous structure. The silicate filaments in the slag also protect the iron from corrosion and may diminish the effect of fatigue caused by shock and vibration.
Historically, a modest amount of wrought iron was refined into steel, which was used mainly to produce swords, cutlery, chisels, axes, and other edged tools, as well as springs and files. The demand for wrought iron reached its peak in the 1860s, being in high demand for ironclad warships and railway use. However, as advances in ferrous metallurgy improved the quality of mild steel, and as the Bessemer process and the Siemens–Martin process made steel much cheaper to produce, the use of wrought iron declined.
Many items, before they came to be made of mild steel, were produced from wrought iron, including rivets, nails, wire, chains, rails, railway couplings, water and steam pipes, nuts, bolts, horseshoes, handrails, wagon tires, straps for timber roof trusses, and ornamental ironwork, among many other things.
Various 19th-century investigations of boiler explosions, especially those by insurance companies, found causes to be most commonly the result of operating boilers above the safe pressure range, either to get more power, or due to defective boiler pressure relief valves and difficulties of obtaining reliable indications of pressure and water levels. Poor fabrication was also a common problem. Also, the thickness of the iron in steam drums was low, by modern standards.
By the late 19th century, when metallurgists were able to better understand what properties and processes made good iron, iron in steam engines was being displaced by steel, whilst the old cylindrical boilers with fire tubes were displaced by inherently safer water tube boilers. demonstrated in England by analysis that a wrought iron bloom, from a traditional smelt, could be worked into 99.7% pure iron with no evidence of carbon. It was found that the stringers common to other wrought irons were not present, thus making it very malleable for the smith to work hot and cold. A commercial source of pure iron is available and is used by smiths as an alternative to traditional wrought iron and other new generation ferrous metals.
Applications
Wrought iron furniture has a long history, dating back to Roman times. There are 13th century wrought iron gates in Westminster Abbey in London, and wrought iron furniture seemed to reach its peak popularity in Britain in the 17th century, during the reign of William III and Mary II. However, cast iron and cheaper steel caused a gradual decline in wrought iron manufacture; the last wrought ironworks in Britain closed in 1974.
It is also used to make home decor items such as baker's racks, wine racks, pot racks, etageres, table bases, desks, gates, beds, candle holders, curtain rods, bars, and bar stools.
The vast majority of wrought iron available today is from reclaimed materials. Old bridges and anchor chains dredged from harbors are major sources. The greater corrosion resistance of wrought iron is due to the siliceous impurities (naturally occurring in iron ore), namely ferrous silicate.
Wrought iron has been used for decades as a generic term across the gate and fencing industry, even though mild steel is used for manufacturing these "wrought iron" gates. This is mainly because of the limited availability of true wrought iron. Steel can also be hot-dip galvanised to prevent corrosion, which cannot be done with wrought iron.
See also
- Bronze and brass ornamental work
- Cast iron
- Semi-steel casting