Aluminum Saw Blade Review: Choosing the Right Blade for the Job

Aluminum saw blades are specifically designed to cut aluminum and other non-ferrous metals like copper and brass. Unlike blades for wood or steel, aluminum saw blades feature a higher tooth count and thinner kerf to achieve clean, burr-free cuts. When selecting an aluminum saw blade, there are several key factors to consider to ensure optimal performance and extended blade life.

  • Tooth Count: Aluminum saw blades typically have a tooth count ranging from 60 to over 100 teeth. Higher tooth counts translate to finer cuts with minimal material chipping. For thin sheet metal applications, a blade with 80 or more teeth is ideal. Conversely, thicker aluminum extrusions can be effectively cut with a blade sporting a tooth count in the 60-80 range.

dewalt-circular-saw-blade-inch-3-tooth-aluminum-cutting Aluminum Saw Blade Review: Choosing the Right Blade for the Job picture

  • Tooth Grind: The tooth grind refers to the shape and angle of the teeth. Two common grinds for aluminum saw blades are Alternate Top Bevel (ATB) and Flat Grind (FG). ATB grinds feature teeth that alternate in bevel direction, creating a shearing action that minimizes chip formation. FG blades, on the other hand, have teeth with a flat profile, suitable for smooth cuts on both sides of the material.
  • Material Thickness: The thickness of the aluminum being cut plays a crucial role in blade selection. Thin kerf blades, typically measuring around 1/16th of an inch, are ideal for thin sheet metal to reduce wasted material. Conversely, thicker aluminum requires a more robust blade with a wider kerf to maintain stability and prevent blade warping.
  • Diamond-Tipped Blades: For exceptional cutting performance and extended blade life, diamond-tipped aluminum saw blades are a superior option. Industrial applications involving frequent aluminum cutting benefit significantly from these blades due to their superior wear resistance.
  • Saw Compatibility: Ensure the chosen aluminum saw blade has the appropriate arbor size and diameter to fit your specific saw. Common arbor sizes include 5/8-inch and 1-inch, while diameters typically range from 7-1/4 inches to 12 inches.
  • Conclusion:
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Selecting the right aluminum saw blade guarantees clean, precise cuts and prevents unnecessary material waste or blade damage. By considering factors like tooth count, grind type, material thickness, and saw compatibility, you can choose the optimal blade for your aluminum cutting needs.

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