Cutting Aluminum

Matthew L

Member
Hi everybody,
I was wondering what the best way to cut aluminum tubing and sheet is. I have heard miter saw or skil saw, but I don't know what blades. Thanks, Matthew L
 
Fine pitch (many teeth) carbide works well Face shield mandatory the chips are scorching hot. A plasma torch is faster on the sheet metal. Jim
 
If you don't have a lot to cut, a regular carbide blade will work.

You can get a carbide blade for metal.

Works well, but not indestructible. The teeth are round instead of squared on the end. Lowes, HD.
 
Make sure the saw is at full rpm before starting the cut, and beyond the end of the cut to avoid kickback if using a toothed blade.
 
A fine tooth carbide blade on a Skil saw works. So does a plasma cutter. I second the face shield and add wearing safety glasses along with hearing protection. Keep your shirt closed plus your mouth.
Those little chips just try to find a way into everywhere you don't want them.
 
If a tool can be used to cut wood or steel, you can probably use it on aluminum. Woodcutting bandsaw, die grinder, abrasive cutoff wheel, skil saw, router, saber saw,... I've used them all.

If you want a super smooth straight cut on sheet of aluminum, you can rough cut it with whatever, then clamp an angle iron to the sheet and make a finish pass with a router, using the angle iron as a guide.
 
Hello Matthewl

You did not say what size-thickness? As a rule aluminum is cut at a lower speed then some other metals, but on a pinch, of small cutting job, a rip blade on a skill saw will make the chips fly! If the blade is carbide tipped that much better. Set 1/2 of the cutter just below the peice if you are cutting a flat peice, and buy go to it!

Guido.
 
Hello Matthew L,

Go to it, pretty thin. It would help if you can cut at a lower speed the then saw you have, but not that important for the thickness.

Guido.
 
I use a negative rake blade on my chop saw to cut thicker aluminum, like extruded 80/20 pieces. Haven't tried it on any thin stuff though.
 
If you are going to cut very much it might be a good idea to get a metal cutting bandsaw. Cutting anything round with a miter saw or skil saw can be very dangerous. While it will work if you take too much and it grabs it will spin the tubing. The sheet metal can be cut alright with the skil saw and would be better to use an aluminum cutting blade. Not the carborundom blades but a fine tooth blade made for aluminum. https://www.mutualscrew.com/product/ivy-classic-aluminum-plastic-circular-saw-blade-swift-cut-143537.cfm?source=froogle&gclid=EAIaIQobChMIr6D6uvqx1gIVDYhpCh09cg4mEAQYAiABEgIKLfD_BwE
 
(quoted from post at 12:28:20 09/19/17) If you are going to cut very much it might be a good idea to get a metal cutting bandsaw. [b:5c5cf91a5c]Cutting anything round with a miter saw or skil saw can be very dangerous. While it will work if you take too much and it grabs it will spin the tubing. The sheet metal can be cut alright with the skil saw and would be better to use an aluminum cutting blade. Not the carborundom blades but a fine tooth blade made for aluminum. [/b:5c5cf91a5c]https://www.mutualscrew.com/product/ivy-classic-aluminum-plastic-circular-saw-blade-swift-cut-143537.cfm?source=froogle&gclid=EAIaIQobChMIr6D6uvqx1gIVDYhpCh09cg4mEAQYAiABEgIKLfD_BwE
i:5c5cf91a5c]
Eh, you take the 'fun' out of it. *lol*

I was using my 17 cu ft Agri Fab lawn trailer as a sawhorse some years back (plywood) and cut about an inch into the steel edge, so circular saws with carbide blades will definitely cut! I didn't even feel it - just heard the difference in pitch. [/i:5c5cf91a5c]
 
Whatever you decide to use, consider a dust respirator, or even a type two. (works better with safety glasses, so they don't fog up) Never expose yourself to aluminum dust or stainless dust. They don't rust out.
 
I've used a regular carbide blade in both an electric hand saw and mitre saw to cut tons of aluminum and it works great. Just cut slow so it doesn't catch. Doesn't even dull the blade. I also use a band saw and that also works great if you treat the blade so the aluminum doesn't stick. A dry band saw blade will quickly build up with aluminum. I use regular mug nozzle spray on mine, but candle wax works too. You can use wd40 or similar, but that can mess with welding. A plasma cutter works goid too if you have one.
 
Why does everyone want to make it so difficult to cut aluminum, just mark your cut and pour liquid dish soap on line and cut with skill saw, table saw, or power miter box. JUST use a saw blade for the .060?, like a veneer blade, ya need at least 2 teeth in contact with what ever thickness you are cutting. Any time you use a abrasive stone on aluminum, the aluminum will gual up on the stone and ruin it!!!

You can use new motor oil also, lot more messy, where dish soap cleans off with water.

Just cut a piece of 1/4in aluminum diamond plate on my table saw. Ya don't even need saw blade with carbide teeth!!!!
 
You can get non ferrous blades for a circular saw. We cut extrusions with them.
Plasma cutter works nice on sheet aluminum.
 

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