The experience obtained year after year in the wear of rails under 190
heavy traffic, led to continued improvements both in the method of
rolling and in the selection of the iron to form the rail-pile; one
description of iron was found more suitable for the head, or running
surface, and another for the vertical web; but, even with the best
machinery and most carefully assorted materials, high-class
wrought-iron rails were liable to lamination, and long thin strips of
iron became detached from the upper, or wearing, surface. The rail was
composed of many layers of iron, and it was not always possible to
ensure that they were all thoroughly welded, or incorporated together.
As early as 1854 a few experimental solid steel rails were laid down
on some of the principal railways, and gave excellent results as to
evenness of wear and durability, but their cost of manufacture
rendered their extended use almost prohibitory.
Compound rails of steel and wrought-iron, as in Fig. 260, were also
tried on several railways, but the practical results were not such as
to lead to a very extended adoption. In preparing the _pile_ for a
compound rail, suitable wrought-iron bars were placed to form the
lower member or flange, the web, and part of the head, and a slab of
steel was placed on the top to form the upper portion of head, or
wearing surface of the rail. It was intended that in the process of
rolling these distinct layers were to be incorporated together, to
form the section shown in Fig. 260. Doubtless many good wearing rails
were manufactured on this system, but the inherent difference of the
two materials, steel and iron, rendered it very difficult to ensure
such uniform incorporation as would withstand the constant pounding
under heavy, fast traffic. It was not until some years later that the
process of the Bessemer Converter was discovered and perfected, by
means of which steel can be produced in large quantities far more
rapidly and at much less cost than by any other method hitherto
adopted. The introduction of this process for making steel caused a
complete revolution in the material for rails. Steel which had
previously been excluded on account of its cost, could now be supplied
at a moderate price, and, from its compact and homogeneous character,
promised a very much longer wearing life than the best wrought-iron
rails that had ever been rolled. Experience has shown that these
promises have been fully verified; wrought-iron rails are things of
the past, steel rails have taken their place, and can now be purchased 191
at a less price per ton than the iron rails of twenty years ago.