Cast iron is made by re-melting pig iron, often along with substantial quantities of scrap iron and scrap steel and taking various steps to remove undesirable contaminants. Phosphorus and sulphur 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 to 3.5% and 1 to 3% respectively.
Cast iron's properties are changed by adding various alloying elements, or alloyants. Next to carbon, silicon is the most important alloyant because it forces carbon out of solution. Instead the carbon forms graphite which results in a softer iron, reduces shrinkage, lowers strength, and decreases density. Sulfur, when added, forms iron sulfide, which prevents the formation of graphite and increases hardness.
Cast iron can be welded directly to steel or iron. However, cast iron gives a rough, bubbled weld, and usually need to be expertly ground down.