Can You Cut Aluminum with a Wood Blade

September 23, 2022

Can You Cut Aluminum with a Wood Blade

Always utilize the correct tools that are designed for the material at hand. Because aluminum is a strong metal compared to wood, many people are hesitant to cut it using a wood blade. If you take the proper measures, it is possible to utilize a wood blade.

Cutting Aluminum With A Wood Blade

Can I cut aluminum with a miter saw? You can work with aluminum using a miter saw and a non-ferrous metal cutting blade. For chopping aluminum extrusions, channels, pipelines, etc., a miter saw is a suitable option. But can you cut aluminum with a wood blade on a miter saw?

Aluminum is effortless to cut and has high machinability. Aluminum can be sliced with a wooden blade with many teeth.

It should be mentioned that non-ferrous materials can be cut with the majority of wood blade brands. Even specific grades of carbide made for cutting aluminum are available. However, you must consider the blade's TPI or several teeth if you intend to utilize a wood blade.

Wood Blade On Aluminum

The number of teeth on the blade is the most significant factor. The cut will be smoother the more teeth there are (greater TPI). Lower TPI blades feature more prominent teeth and deep gullets. These will move the workpiece towards the direction of the blade by grabbing the aluminum channels' edges.

Use a blade with more than 10 teeth per inch of diameter when cutting less than 1/16th of an inch thick aluminum. In other words, if you have a 12-inch miter saw, utilize a blade with 120 teeth.

10 TPI x 12 Inch Blade Diameter = 120

Many companies make these wood cutting blades with up to 200 teeth for that purpose. You must use a blade with 10 teeth per diameter inch if the aluminum is thicker, such as 1/8th of an inch. There are just 8 teeth per inch of diameter for a thickness of 1/4 of an inch. The maximum tooth density is six per inch for aluminum thicker than a quarter inch.

Can A Chop Saw Be Used To Cut Aluminum?

Yes, if by chop saw, you mean a miter saw. You can cut aluminum using a non-ferrous metal cutting blade and a chop saw (miter saw). Avoid using an abrasive disc to remove aluminum on a chop saw designed for cutting metal. Aluminum will jam abrasive cutting discs, causing them to overheat and shatter.

Using A Circular Saw To Cut Aluminum

The miter saw is not an option for cutting huge aluminum sheets. A circular saw or jigsaw with metal cutting blades is the appropriate tool to employ in these circumstances. With a non-ferrous circular saw blades or a delicate wood blade with a carbide tip, you can use a circular saw to slice aluminum. Take your time and move slowly using a handheld circular saw to slice aluminum. If the cut is not straight, the metal will catch it. When this occurs, let go of the trigger and slightly retract the saw. Once more, feed the saw slowly and let the blade do the cutting.

Tips For Proper Aluminum Cutting

Keep The Workpiece Safe

The most crucial piece of advice for using a blade designed for wood to cut aluminum is to take the necessary safety measures. This entails making sure the material is securely fastened.

The workpiece can be held in your hand while cutting with a miter saw in woodworking. Aluminum, however, has a propensity to stick to the blade and can be harmful. To ensure that the metal stays in place, it is advisable to use many clamps.

Wear PPE

You should wear safety goggles and clothing that is reasonably close to your skin as a general rule for safety. Loose clothing may catch if you are too close to the blade while it is moving. Remove any rings or jewelry that could catch on the blade as well. As a result, you shouldn't wear too loose gloves because they could get caught on the rotating blade. Be mindful of a scrap of fabric adhering to the cut edges. These can cut your fingers because they are sharp.

Cut-Off Piece

The cut-off section being dragged with strong force toward the blade is among the most hazardous parts of chopping aluminum. Serious injury could occur if the cut-off piece flies in your direction. You can wear a full safety mask or shield that will protect your face and neck in place of safety eyewear. To prevent it from being pulled by the blade, you might clamp a piece of wood to the side of the cut-off work.

Use Cutting Oil

Another crucial component of cutting aluminum is the use of cutting oil. The main risk is that the material will catch or get caught in the saw, which could lead to splinters. If that occurs, it is possible that anyone nearby will be struck by the shrapnel created by the blade or aluminum splintering off quickly. Before working on the aluminum workpiece, strongly advise clamping it.

To prevent the blade from being clogged with debris or catching on the aluminum itself, be sure to lubricate it with a low viscosity cutting oil. The lubrication keeps the blade and aluminum cooler, lowering the risk of splintering and preventing overheating.

Employ A Fine Blade

For cutting metal, make sure the wood blade you select has a fine blade with many teeth. Always have plenty of oil on the blade, and let the blade cool slightly in between cuts. This will lessen the possibility of harm and keep the material intact.


Hope this post will be helpful to you as you choose your blade. The blade must be suitable for cutting non-ferrous materials and have the appropriate number of teeth for the thickness of the aluminum.

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