Cast iron
Cast iron is made from pig iron, which is the product of smelting iron ore in a blast furnace. Cast iron can be made directly from the molten pig iron or by re-melting pig iron, often along with substantial quantities of iron, steel, limestone, carbon (coke) and taking various steps to remove undesirable contaminants. Phosphorus and sulfur may be burnt out of the molten iron, but this also burns out the carbon, which must be replaced. Depending on the application, carbon and silicon content are adjusted to the desired levels, which may be anywhere from 2–3.5% and 1–3%, respectively. If desired, other elements are then added to the melt before the final form is produced by casting.
Rail transport
Cast iron used in rails proved unsatisfactory because it was brittle and broke under heavy loads. The wrought iron invented by John Birkinshaw in 1820 replaced cast iron. Wrought iron (usually simply referred to as "iron") was a ductile material that could undergo considerable deformation before breaking, making it more suitable for iron rails. But iron was expensive to produce until Henry Cort patented the puddling process in 1784. In 1783 Cort also patented the rolling process, which was 15 times faster at consolidating and shaping iron than hammering. These processes greatly lowered the cost of producing iron and rails. The next important development in iron production was hot blast developed by James Beaumont Neilson (patented 1828), which considerably reduced the amount of coke (fuel) or charcoal needed to produce pig iron. Wrought iron was a soft material that contained slag or "dross". The softness and dross tended to make iron rails distort and delaminate and they lasted less than 10 years. Sometimes they lasted as little as one year under high traffic. All these developments in the production of iron eventually led to replacement of composite wood/iron rails with superior all iron rails.