As a metallurgical expert with a keen interest in the history of materials, I can provide a detailed explanation of why the material is called "cast iron." The term "cast iron" is derived from the process of manufacturing this type of iron, which involves the use of a casting process. Let's delve into the history and the production process to understand why this name is so fitting.

Cast iron has been used for thousands of years, with archaeological evidence suggesting its use as early as the 5th century BCE in China. The process of creating cast iron involves reducing iron ore in a blast furnace, a method that has been refined over centuries. The blast furnace is a tall structure that allows for the continuous smelting of iron from iron ore, which is a mixture of iron oxides and other impurities. The reduction process involves the use of coke, which is a form of carbon derived from coal, and limestone, which acts as a flux to remove impurities.

The liquid iron produced in the blast furnace is at a very high temperature, typically around 1,500 to 1,600 degrees Celsius. This molten iron is then cast, or poured, into molds. The term "cast" refers to the process of pouring a liquid material into a mold and allowing it to solidify. In the case of cast iron, the molds can take various shapes and sizes, depending on the end product that is desired.

After the iron has solidified in the molds, it forms what are known as "pigs." The origin of the term "pig iron" is somewhat debated, but it is believed to have come from the shape of the ingots, which were often grouped together and had a shape reminiscent of suckling piglets. These crude ingots, or pigs, are not yet the final product. They are relatively high in carbon and other impurities, making them brittle and not suitable for many applications.

To produce a more refined form of cast iron or even steel, the pigs are remelted in a cupola furnace, which is a type of furnace that uses a continuous tapping process. The cupola furnace allows for the addition of scrap and alloying elements to the molten iron. These alloying elements can include carbon, silicon, manganese, and others, which are used to adjust the properties of the final product. The addition of these elements and the process of remelting and casting again allow for the production of a variety of cast iron products with different characteristics.

The casting process is central to the production of cast iron, and it is this process that gives the material its name. The ability to cast iron into intricate shapes and designs is one of the reasons for its widespread use in history, particularly in the production of cookware, pipes, and machinery components.

In summary, the term "cast iron" is a reflection of the material's production method, which involves the casting of molten iron into molds to create a variety of products. The process is a testament to human ingenuity and the material's versatility, which has been valued for centuries.

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It is made by reducing iron ore in a blast furnace. The liquid iron is cast, or poured and hardened, into crude ingots called pigs, and the pigs are subsequently remelted along with scrap and alloying elements in cupola furnaces and recast into molds for producing a variety of products.read more >>