Wrought steel and cast steel are often mistaken for similar materials, but they are actually quite different. Both are types of steel, but their production methods, properties, and applications set them apart. Understanding these differences can help you choose the right material for your project.
Wrought steel is produced by heating the metal and then shaping it using tools and machinery. This process allows for greater control over the final product, making it more ductile and easier to work with. On the other hand, cast steel is made by melting iron and pouring it into a mold, where it solidifies into the desired shape. This method is ideal for creating complex parts that would be difficult to produce through other means.
Wrought steel is known for its high ductility and strength. It can be reheated and reshaped multiple times, which makes it highly versatile. Compared to cast iron, it contains less carbon, which gives it better malleability and ease of use in various applications. Here are some key benefits of wrought steel:
- Excellent welding properties, allowing for flexible shaping based on application needs.
- High flexibility and ductility, making it suitable for applications requiring adaptability.
- Strong tensile strength, ideal for use in harsh environments or high-stress situations.
- Easy to forge, enabling the creation of intricate and detailed shapes.
Cast steel, on the other hand, has a higher carbon content (typically 2.0–4.0%) and includes elements like manganese and silicon. It is created by melting iron ore and combining it with other metals and alloys. The molten mixture is then poured into a mold and allowed to cool and harden. While it is harder and more brittle than wrought steel, it offers excellent compressive strength and durability. Here are some advantages of cast steel:
- High compression strength, offering resistance to pressure and stress.
- Good durability, which can be enhanced through alloying and heat treatment.
- Excellent machinability, making it easy to cut, drill, and shape as needed.
- Superior wear resistance, especially when elements like chromium or molybdenum are added.
Table of contents
- Difference between wrought steel and cast steel
- Heat Treatment of cast steel
- Advantages and Disadvantages of cast iron steel
- Advantages of wrought iron
- Puddling process vs Metal Casting process
- Types of cast iron
- Properties of 4140 cast steel
- Chemical composition of Cast iron
- Cast Iron mechanical properties
- AISI 4140 Heat Treatment
- Wrought Iron chemical composition
- Wrought Steel mechanical properties
- Inspection and Testing of Cast steel
- Manufacturing process of 4340 steel casting
- Cast steel valves temperature range
- Difference between Wrought Iron and Steel
- Surface finish of Cast iron parts
Difference between wrought steel and cast steel
| Wrought Iron |
Cast Iron |
| It is iron that has been heated and then worked with tools. |
It is iron that has been melted, poured into a mold, and allowed to solidify. |
| It is brittle. |
It is ductile. |
| Higher tensile strength. |
Lower tensile strength compared to Wrought Iron. |
| Low melting point. |
High melting point. |
| Difficult to weld. |
Easily welded. |
Right technique for welding cast steel, check 4140/ 4340 Steel Heat Treatment and Casting hardness
Heat Treatment of cast steel
- Annealing
- Precipitation Strengthening
- Tempering
- Case Hardening
- Normalising
- Quenching
Refer advantages of Cast and Wrought Steel products
Advantages and Disadvantages of cast iron steel
Advantages
- Cast iron has excellent fluidity after melting.
- High Wear Resistance.
- Excellent Machinability.
- Compression Strength.
- Low Cost.
Disadvantages
- It is relatively brittle and may fracture.
- Very easily rusted.
- It is relatively heavy.
Advantages of wrought iron
- Increased ductility.
- Excellent weldability.
- Easily forged.
- High tensile & compressive strength.
- Enhanced malleability.
Check difference between puddling of cast iron and Metal Casting process
Puddling process vs Metal Casting process
The puddling process involves converting pig iron into wrought iron by heating and stirring it in a furnace without the use of charcoal. This was one of the earliest methods for producing wrought iron in large quantities. In contrast, metal casting involves pouring molten metal into a mold to create the desired shape. This process is ideal for making complex components that would be difficult or expensive to produce otherwise.
Types of cast iron
Gray Cast Iron
Ductile Cast Iron
White Cast Iron
Malleable Cast Iron
Properties of 4140 cast steel
- Hardness
- Ductility
- Wear resistance
- Corrosion resistance
- Toughness
- Strength
- Machinability
- Weldability
- Low-temperature properties
- High-temperature properties
Types of Cast Steel material, check grades, composition, and density in kg/m3
Chemical composition of Cast iron
| ASTM |
Chemical Requirements |
| STEEL GRADE |
Carbon |
Manganese |
Silicon |
Sulfur |
Phosphorus |
| Max % / Range |
| ASTM A27 / A27M |
| Grade N-1 |
0.25 |
0.75 |
0.80 |
0.06 |
0.05 |
| Grade N-2 |
0.35 |
0.60 |
0.80 |
0.06 |
0.05 |
| Grade U60-30 |
0.25 |
0.75 |
0.80 |
0.06 |
0.05 |
| Grade 60-30 |
0.30 |
0.60 |
0.80 |
0.06 |
0.05 |
| Grade 65-35 |
0.30 |
0.70 |
0.80 |
0.06 |
0.05 |
| Grade 70-36 |
0.35 |
0.70 |
0.80 |
0.06 |
0.05 |
| Grade 70-40 |
0.25 |
1.20 |
0.80 |
0.06 |
0.05 |
| ASTM A148 / A148M |
| Grade 80-40 |
N/A |
N/A |
N/A |
0.06 |
0.05 |
| Grade 80-50 |
N/A |
N/A |
N/A |
0.06 |
0.05 |
| Grade 90-60 |
N/A |
N/A |
N/A |
0.06 |
0.05 |
| ASTM A216 / A216M |
| Grade WCA |
0.25 |
0.70 |
0.60 |
0.045 |
0.04 |
| Grade WCB |
0.30 |
1.00 |
0.60 |
0.045 |
0.04 |
| Grade WCC |
0.25 |
1.20 |
0.60 |
0.045 |
0.04 |
Cast Iron mechanical properties
| ASTM |
Mechanical Properties |
| STEEL GRADE |
Tensile Strength |
Yield Point |
Elongation in 2 in. |
Reduction of Area |
| Min. ksi [Mpa] / Range |
Min. % |
| ASTM A27 / A27M |
| Grade U60-30 |
60 [415] |
30 [205] |
22 |
30 |
| Grade 60-30 |
60 [415] |
30 [205] |
24 |
35 |
| Grade 65-35 |
65 [450] |
35 [240] |
24 |
35 |
| Grade 70-36 |
70 [485] |
36 [250] |
22 |
30 |
| Grade 70-40 |
70 [485] |
40 [275] |
22 |
30 |
| ASTM A148 / A148M |
| Grade 80-40 |
80 [550] |
40 [275] |
18 |
30 |
| Grade 80-50 |
80 [550] |
50 [345] |
22 |
35 |
| Grade 90-60 |
90 [620] |
60 [415] |
20 |
40 |
| ASTM A216 / A216M |
| Grade WCA |
60-85 [415-585] |
30 [205] |
24 |
35 |
| Grade WCB |
70-95 [485-655] |
36 [250] |
22 |
35 |
| Grade WCC |
70-95 [485-655] |
40 [275] |
22 |
35 |
AISI 4140 Heat Treatment
| Soft annealing °C |
Cooling |
Hardness HB |
| 650-700 |
slowly |
max. 280 |
| Stress-relief annealing °C |
Cooling |
| 630 – 650 |
Furnace |
| 1st pre-heating °C |
2nd and 3rd |
Hardening °C |
Quenching |
Tempering °C |
Hardness after Teperature HRC |
| up to approx. 400 in an air-circulating furnace |
780 and 1000 |
1190 – 1230 |
Saltbath, at least 520 °C Oil ,Air |
at least twice 530-560 |
64 – 66 |
Wrought Iron chemical composition
| Element |
Iron, Fe |
Carbon, C |
Phosphorus, P |
Silicon, Si |
Sulfur, S |
Manganese, Mn |
| Content (%) |
99-99.8 |
0.05-0.25 |
0.05-0.2 |
0.02-0.2 |
0.02-0.1 |
0.01-0.1 |
Wrought Steel mechanical properties
| Properties |
Imperial |
Metric |
| Tensile strength |
34000-54000 psi |
234-372 MPa |
| Modulus of elasticity |
28000 ksi |
193100 MPa |
| Yield strength |
23000-32000 psi |
159-221 MPa |
Inspection and Testing of Cast steel
- Dimensional accuracy
- Surface finish condition
- Internal soundness
- Chemical analysis
- Heat analysis
- Tensile properties
- Impact properties
- Hardness
Manufacturing process of 4340 steel casting
- Furnace charging
- Melting
- Refining
- De-slagging
- Tapping (or tap out)
- Furnace turn-around
Refer cast steel valves uses and temperature limit
Cast steel valves temperature range
| Temperature range |
-29°C to 425°C |
Difference between Wrought Iron and Steel
| Characteristics |
Wrought Iron |
Steel |
| Carbon content |
0.08% |
4% |
| Tensile Strength |
Very good tensile strength |
Greater tensile strength |
| Workmanship |
Requires less workmanship. |
Requires more craftsmanship than wrought iron |
Surface finish of Cast iron parts
- Shot Blasting
- Painting
- Powder Coating
- Electroplating
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