Cutting Aluminum: How to Choose the Right Saw Blade Complete Guide

Are you struggling with finding the right saw blade for cutting aluminium? Don’t know where to begin? You’re in luck!

This guide has all the information you need to make the right choice and get perfect cuts in aluminium.

Choosing the right saw blade for your aluminium cutting project is an important decision. The right blade will reduce the time it takes to finish a job, and it can be the difference between a successful cut and one that fails. This guide will provide an overview of what to look for when selecting a saw blade for cutting aluminium.

When choosing a saw blade for cutting aluminum, it’s essential to consider the characteristics of the material being cut and how they interact with the blade. When considering characteristics such as hardness, composition, and grain structure, one must also factor in their own experience level. While evaluating all of these elements may seem daunting at first, this comprehensive guide can make your choice easier by taking you through each step one by one.

We’ll start by looking at some of the common types of blades used for cutting aluminum and explain what makes each type effective or ineffective when dealing with this material. Since aluminum comes in different forms, we will explore which saw blades are best suited for each situation so that you can make an informed decision on which type is best for you. We will also discuss tips on setting up your saw correctly to ensure optimal performance from whatever type of blade you decide on. Lastly, we’ll provide some maintenance tips so that you can keep your saw blades functioning properly even with frequent use. Whether you are already experienced with cutting aluminum or just starting out in this area, this guide should offer everything necessary to make sure that your next project succeeds without any complications!

Explanation of why choosing the right saw blade is important

Choosing the right saw blade is integral to successful cutting of aluminum. Using a saw blade that is not specifically designed for cutting aluminum can cause poor cuts, material damage and dulling of the blade. Taking the time to select the right saw blade can increase efficiency, production and create a higher quality finished product.

It’s important to consider factors such as ferrous metals vs. non-ferrous metals, tooth geometry and saw blade style when it comes to selecting the specific saw blade for aluminum jobs. The following guide outlines what you should know in order to properly choose a saw blade for cutting aluminum every time.

Brief overview of cutting aluminum

Aluminum can be cut using a variety of hand-held and stationary saws such as reciprocating, band and miter saws. The type of saw used depends on the size and shape of the aluminum stock being cut. For smaller pieces of aluminum, such as multi-ply sheets, thin strips or piles of shavings, a handheld reciprocating saw blade with carbide-tipped teeth is an ideal choice. A more accurate cut can be achieved with a stationary miter or band saw that employs a blade specifically designed for cutting aluminum.

When selecting the type of blade to use for cutting aluminum, know that aluminum is most easily cut when it is cool and free from stress. Carbide-tipped blades offer superior performance when cutting cold aluminum due to their higher heat resistance, longer life span and faster feed rate than ordinary steel blades. It is important to select the correct blade regardless of what type of saw you are using in order to get the best results possible without damaging your work surface or ruining your work piece.

Factors to Consider When Choosing a Saw Blade

When designing a cut pattern for an aluminum project, choosing the right saw blade can make the difference between a successful job and an unusable part. Whatever the application, there are several factors to bear in mind when selecting an aluminum cutting saw blade. These include the blade’s width, tooth geometry and size, kerf or width of cut per tooth along with cost and type of metal being cut.

The correct tooling choice is determined by assessing blades designed for different metal types and understanding the different cutting tasks they are designed to perform. Aluminum is notorious for causing problems because it’s a soft material that dulls saw blades quickly. For consistent performance it is important to choose the best tooling solution suited to your particular job.

Let’s explore these factors in greater detail:

– Blade Width: The wider the blade is, the faster it will feed into material resulting in higher productivity; however, wider blades require heavier equipment for increased stability and may break easier due to loss of rigidity if used on smaller machines.

– Tooth Geometry: This determines how quickly each tooth removes chips from your workpiece resulting in smoother cuts with fewer burrs left over after cutting operations. Look for blades that offer efficient chip evacuation for better results on aluminum cutting applications.

– Tooth Size: Teeth must be large enough to handle a given depth of cut without exceeding their tension strength rating; otherwise, they can flex more easily leading to more vibrating which translates into poorer cutting performance. Smaller teeth lead to finer finishes while larger teeth are better suited for heavy-duty applications requiring faster speeds while still maintaining accuracy.

– Kerf: Kerf (the width of cut per tooth) should match or exceed job requirements or else your results won’t be accurate in terms of dimensions or shape outline accuracy once machined parts have been taken out of cuts as each chip removal affects final product quality when using traditional mechanical methods like cold saw blades. Choosing thicker kerfs takes longer but provides cleaner results as there is less room available inducing less tearing while thinner kerfs provide faster feeds but may result in chipping where corners meet relatively sharp acute angle variations.

– Cost & Metal Type Being Cut: All blades since their inception have been made from different grades steel that vary considerably such as high speed steel (HSS), particle metal (PM), carbide tipped (CT) and Bi-metal soldered (BS) categories offering various degrees of edge retention depending on slicing complexity & volume done per session along with metal type & thickness being dealt with at any given time. Knowing what type of metal you’re slicing ahead & how frequently/infrequently will help you pick optimal properties required whether fine edge finishing details demanded by custom finishings |or intense mass production specs needing stack scissor like slicings prolonged durability on both cost & performance aspects wise.

Thickness and hardness of aluminum being cut

Aluminum is a unique material due to its thickness and hardness. When selecting the right saw blade for cutting aluminum, you need to take into account the thickness and hardness of the aluminum being cut. Generally speaking, thicker and harder aluminum will require blades with more teeth per inch (TPI). This is because larger blades with fewer teeth may create rougher cuts while smaller blades with more teeth can make smoother cuts.

Also, thicker and harder aluminum will require slower speeds on the saw to prevent overheating and melting of the aluminum material. Slower speeds also allow for better accuracy which is important when making precise cuts.

Before starting any project involving cutting aluminum, it’s important to know the correct size of blade for your particular application as well as the suitable speed for your saw’s configuration.

Blade diameter and thickness

The diameter and thickness of the blade will determine which type of saw is best suited to cut aluminum. For precise cutting, smaller blade diameters may be best, as they allow you to make precise cuts that won’t leave extra metal. For larger projects however, thicker blades are more suitable.

The size of the main slot in your saw should be determined by the size of your material before selecting a blade. Your choice will depend on whether you are cutting rods, tubes or sheet metal, since each type requires its own blade guidelines.

Generally speaking, it is best if the size of the saw is at least 5 times longer than the material you are cutting in order to ensure that it pairs up with a true section and provides a clean cut without vibration or wasting material.

Choosing the Right Saw Blade for the Job

When choosing the right saw blade for the job, there are several factors to consider including blade material, blade teeth size and number of teeth per inch (TPI), gullet size, and kerf. All of these factors play a role in how efficiently a saw blade can cut through aluminum.

Blade Material: There are three main types of saw blades available for cutting aluminum – carbide-tipped saw blades, high-speed steel (HSS) saw blades, and diamond-tipped or coated saw blades. Each type has its own set of characteristics and features that make it suitable for certain tasks. Carbide-tipped blades tend to be long lasting and durable while HSS and diamond cutters are designed with increased efficiency in mind. When selecting a blade material, take into consideration the type and thickness of aluminum being cut into – small or thin materials can usually be handled with HSS while large chunks may require carbide tip or diamond tipped/coated steel blades.

TPI & Gullet Size: A blade’s TPI is determined by the number of teeth per inch on its circumference. Higher TPI values indicate a finer finish quality on more delicate materials, however lower TPI values allow for faster cutting speeds on heavier materials like aluminum alloys. The size of the gullet also affects cutting speed – larger gullets help clear chips from the cut faster resulting in better cuts with less friction buildup. Gullet sizes range from small to large; when dealing with softer metals such as aluminum alloys it is recommended to go with a medium sized gullet for increased efficiency.

Kerf: Kerf refers to the width of material being removed when a saw is used which impacts how much pressure needs to be applied on a workpiece as well as how long it takes to complete a cut. When dealing with aluminum alloys it is important that the correct kerf width be selected – too low will cause excessive pressure or inadequate cutting while too high will cause slowed cutting speeds due to an accumulation of chips preventing further advancement along the cut line. It is recommended that you use thinner blades or full kerf models when possible; they will help ensure optimal performance regardless of alloy type being used.

HSS blades for thinner aluminum sheets

High-speed steel (HSS) blades are the most common saw blades that cut aluminum. They come in many different configurations, but they all have one thing in common — they are designed to work specifically with thin material like sheets of aluminum. The majority of HSS blades are made up of a unique alloy containing molybdenum and tungsten, a combination that is known for its wear-resistant properties.

When using HSS blades for cutting sheets of aluminum, the key factor to consider is teeth per inch (TPI). Generally speaking, higher TPI values create smoother cuts. A good rule of thumb is to use at least 80 TPI when cutting softer metals such as aluminum. If you’re going to be cutting deeper material than sheets, then you should consider a blade with fewer TPI because this will help to reduce friction and provide better durability over time by reducing metal buildup on the edge.

HSS blades come in various geometries and metal combinations, so it’s important to choose the right option for your specific type of aluminum cutting job. It’s also important to note that thicker materials may require a blade with large gullets between the teeth — gullets increase chip clearance while cutting which will help reduce friction on thicker pieces.

Choosing the Correct Saw And Saw Blade For Cutting Metal Decking

Carbide-tipped blades for thicker aluminum sheets and extrusions

Carbide-tipped blades are typically recommended for thicker aluminum sheets and extrusion, as they offer superior cutting speed, accurate cuts, and longer blade life. They are engineered with a mix of particles that are sintered together in high heat and pressure to produce a strong substrate.

Carbide-tipped blades can help you save more time in comparison to other saws. They also yield clean edges with minimal material loss. However, these blades can be very hard on equipment due to their abrasive nature; they tend to wear down blade teeth quickly, so they must be changed out often.

For thicker sheets of aluminum of 1/4 inch or more in thickness, opt for a carbide-tipped saw blade made specifically for cutting metal like aluminum.

Diamond blades for cutting non-ferrous metals

For cutting non-ferrous metals like aluminum, copper, brass and bronze, diamond blades are recommended. Choose the right type of diamond blade for the type of metal you need to cut. There are two main types of diamond blades: electroplated surface set blades and sintered core filled blades.

Electroplated surface set blades are good for soft metals like aluminum and copper as they have softer bond segments that generate more heat, resulting in smoother cut surfaces. However, because the diamonds tend to be shallowly imbedded, they wear out faster than other types of saws. Sintered core filled blades are perfect for harder metals since they use a thicker bond segment with deeper diamond particles that keep their cutting edge longer.

Other considerations when choosing a saw include the number of teeth per inch (TPI) and kerf width—the larger the TPI, the finer the finish; and wider kerf results in a faster cut but can also leave more burring along your edge line. The various features all have an impact on cost and performance so select your saw according to these criteria to get optimal results from your project cutting aluminum or other non-ferrous metals.

Maintaining and Caring for Saw Blades

It is important to remember that a saw blade’s life expectancy depends on its use and maintenance. After each use, the saw blade should be cleaned of any residue left behind by the material you’re cutting. This can be done using a wire brush, a soft cloth or a compressed air source. It is also important to lubricate your saw blade before and after each use as this will help maintain sharpness and reduce heat build-up & friction, extending the service life of your blades.

In addition to cleaning and lubricating, it is also important to store your saw blades properly in order to further increase their longevity. Blade teeth are made from hardened steel, so it is important to make sure that the blades are stored away from moisture or high humidity environment. Furthermore, lubricate them before storage if it wasn’t done during use as this acts as an additional barrier from rusting and corrosion which could shorten their life span.

Proper blade cleaning and maintenance

Using the wrong blade, or a poorly maintained blade, can lead to damaged parts, decreased blade life and unsafe working environments. To ensure your saw works properly and last longer, proper cleaning and maintenance of the blades is essential. Here are some tips on maintaining your blade to ensure optimal performance.

  1. Clean the blade every time it is used. You should clean off any dirt, burrs or excess material buildup using either a brush or compressed air nozzle on low pressure.
  2. Make sure that you inspect your blades for stress points and cracks before using them as they can become weaker over time due to use and general wear. If you find any cracks or stress points dispose of the blade immediately to minimize the risk of a cutting accident occurring in the future.
  3. Sharpen your wood cutting saw blades regularly with either a file or stone to increase their longevity – like any knife that is overused it can become dull so to keep up its performance sharpen it every once in awhile!
  4. Lubricate any moving parts such as rails and bearings with oil during regular maintenance checks – this will help ensure that everything is running smoothly and efficiently during operation!

Storage of saw blades

Saw blades are precision tools that need to be kept in top condition for smooth, accurate cuts. To ensure safety and extend the longevity of your saw blades, it is important to store them properly. You should always follow any storage instructions provided by the saw blade manufacturer for best results.

Generally, saw blades should be stored in a cool, dry place away from sources moisture and heat. Most aluminum saw blades come with plastic sleeves or containers designed specifically to protect the blade when it is not in use. Storing your saw blade in a sleeve will help preserve its cutting edge and protect it from damage that could potentially occur during transport or storage. The plastic sleeves may also provide additional layer of dust protection, helping keep your work environment clean beginning to end.

For even better protection, you may want to consider storing multiple saws together in a toolbox or other container if you have an extensive selection of blades on hand and need portability as well as safe keeping options. This method also makes finding the right blade significantly easier since you’ll have all of them together, rather than having them scattered around the shop or work site.

Finally, always make sure that the blades are free of dirt and dust before returning them to their protective sleeves or cases for storage at the end of each job!

Selecting the Proper Saw Blade


Choosing the right saw blade is an important step to ensure successful metal fabrication. Different types of blades have specific features that make them better suited for different types of materials and applications, so take the time to evaluate all your options carefully.

When using aluminum as your material, you should also pay special attention to safety; aluminum has a tendency to trap heat, which can cause serious injury if you’re not prepared for it.

All in all, if you follow these steps and use the right tools for the job, you should be able to achieve excellent results and safely complete any metal fabrication project.


What saw blade should I use to cut aluminum? 

You should use a saw blade that is specifically designed for cutting aluminum.

How do I know what saw blade to use?

You can determine the appropriate saw blade to use by considering factors such as the type of material you are cutting, the thickness of the material, and the type of saw you are using.

What is the best saw blade for cutting aluminum extrusion? 

The best saw blade for cutting aluminum extrusion is one that has a high tooth count and is made of a hard material such as carbide.

What is best for cutting aluminium? 

The best tool for cutting aluminum depends on the specific application, but some options include saws, shears, and plasma cutters.

Will a regular saw blade cut aluminum? 

A regular saw blade may be able to cut aluminum, but it is not recommended as it can cause damage to the blade and may result in an unsafe cutting process.

How many teeth per inch for cutting aluminum? 

For cutting aluminum, a saw blade with a high tooth count, such as 60 to 80 teeth per inch, is recommended.

What is the size of aluminium cutter blade? 

The size of the aluminum cutter blade depends on the specific application and the size of the material being cut.

What is the difference between aluminum and wood saw blade? 

The main difference between an aluminum saw blade and a wood saw blade is the number and shape of the teeth. Aluminum blades have more teeth and often have a finer tooth shape than wood blades.

How do I choose a saw blade for different metals?

 You can choose a saw blade for different metals by considering the type of metal, the thickness of the material, and the type of saw being used.

How do I choose a blade size?

 You can choose a blade size based on the size of the material being cut and the capacity of the saw being used. It is important to ensure that the blade is compatible with the saw and that it is appropriate for the specific application.

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