I have to disagree with the statement that iron is brittle. CAST iron is hard, brittle and unworkable by blacksmith techniques. Even when it is white-hot, pounding on it will cause it to shatter. This is because cast iron is very high in carbon content; as iron is heated towards its melting point, it combines with carbon from the air and especially with available carbon from the fuels used to heat it. Making steel required not just mixing carbon with iron, but limiting and controlling the carbon content, and that was technology the Romans did not possess.
The Romans produced their iron through a "bloomery" smelting process that involved mixing iron ore in the form of hematite or bog iron nodules with charcoal. They introduced enough air into the burning charcoal to keep its temperature up, but part of its combustion air came from the oxygen driven off from the iron oxide, which left behind metalic iron. This process takes advantage of the fact that the impurities lower the melting point of the iron they are mixed with to a "eutectic point" that is less than the melting point of pure iron, and it thereby reduces its tendency to take up free carbon and become unworkable. The product from this was iron "blooms" consisting of a spongelike mass of metalic iron with bits of charcoal and other impurities embedded in it. This picture shows an iron bloom that has been sectioned to show these voids:
Roman - and later - blacksmiths had to re-heat and work these blooms in a process called "fettling", hammering the blooms and gradually working out the large impurities and voids to produce a wrought-iron billet. This was the basis for all of their iron implements, from swords to nails. This iron still contained impurities, mainly silicon, and this led to worked pieces having a characteristic grain-like internal structure. This picture illustrates this, showing a bent and broken piece of wrought iron with its grain structure: Roman-era swords would likely have bent this same way rather than breaking as steel would.
We have some examples of Roman-era wrought-iron from the first century AD in the cache of over 800,000 Roman nails that were recovered at Inchtuthil, in Scotland. You can read more about that at this link: Inchtuthil Roman nails.
Wrought iron is not brittle, but like other soft irons it is not flexible, either. It bends and stays bent. An example of this that everyone is familiar with are common nails, which are generally made of soft iron. They are easily bent and do not spring back - you have to straighten them, and I expect that Roman armorers had to straighten gladii frequently. We know that pilum shafts were intended to bend and stay bent; flexibility would have defeated their purpose. It also meant that an iron sword would require frequent sharpening and was more susceptible to rusting than a steel one would have been.
The Romans may have used a method known as carburizing to case-harden iron blades. This involved heating the piece to a high temperature in the presence of carbon, so that the surface layer would take up carbon and become similar to cast iron, very hard and wear-resistant. But the internal structure of the piece would remain ordinary wrought iron.
Bottom line is that making steel is not as simple as one might believe, and I do not believe that the Romans made it other than accidentally. They were very adept at producing wrought-iron and working it into blades, armor, and many other kinds of implements.
Gromit