Can You Cut Aluminum with a Wood Blade

Always utilize the correct tools designed for the material at hand. Because aluminum is a more robust metal than wood, many people are hesitant to cut it using a wood blade. If you take the right measures, though, you can use a wood blade.

CUTTING ALUMINUM WITH A WOOD BLADE

Wooden blades can cut aluminum, but they won't cut it perfectly since metal cutting blades require sharp teeth and high strength. Here are the reasons:

• Blade Durability—The term "blade durability" describes how long a blade may stay sharp. Compared to metal, wood is a softer substance. Wood blades are intended to cut softer materials. The longevity and effectiveness of wood blades might be impacted when cutting aluminum.

The durability of the blades can also be impacted by cutting speed. Cutting at a fast pace can also cause blade damage.

• Quality of cut—When cutting aluminum, wood blades cannot produce precise and clean cuts. Metal blades, on the other hand, can provide a precise and clean cut because they are made especially for cutting metal.

In contrast to metal blades, wood blades' tooth configuration is specifically made for cutting wood, making them less efficient at removing metal shavings. This may lead to burrs and a harsh finish.

• Safety—Cutting aluminum with metal blades is safer than with wood blades. Metal shavings produced by aluminum have the potential to be hazardous. Because metal blades are made to withstand these circumstances more safely, they are ideal for cutting metal.
• Blade Kickback—When cutting aluminum, the blades can kick back. Consequently, the workpiece may be thrown unexpectedly and injure someone. Thus, metal blades work better than wood ones when cutting aluminum.

Can I cut aluminum with a miter saw? 

YES, You can use a miter saw with a non-ferrous metal cutting blade to cut aluminum. A miter saw is a suitable option for chopping aluminum extrusions, channels, pipelines, etc. But can you cut aluminum with a wood blade on a miter saw?

Aluminum is very easy to cut and has high machinability. It can be cut with a wooden blade and has 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 take into account the TPI or number of teeth of the blade 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 larger teeth and deep gullets. These will move the workpiece toward 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 aluminum that is less than 1/16th of an inch thick. 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 businesses make these wood blades with up to 200 teeth for that purpose. You must use a blade with 10 teeth per diameter 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. For aluminum that is thicker than a quarter inch, the maximum tooth density is six per inch.

CAN A CHOP SAW BE USED TO CUT ALUMINUM?

Yes, if you mean a chop saw, you can cut aluminum using a non-ferrous metal cutting blade and a chop saw (miter saw). On a chop saw designed for cutting metal, avoid using an abrasive disc to remove aluminum. Aluminum will jam abrasive cutting discs, causing them to overheat and potentially 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 a metal-cutting blade is the appropriate tool to employ in these circumstances. With a non-ferrous circular saw blade or a delicate wood blade with a carbide tip, you can use a circular saw to cut aluminum. Take your time and move slowly while using a handheld circular saw to cut 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.

TOP TIPS FOR CUTTING ALUMINUM

1. 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.

In woodworking, the workpiece can be held in your hand while being cut with a miter saw. 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.

2. WEAR PPE

You should wear safety goggles and clothing that is reasonably close to your skin as a general rule for safety. If you are too close to the blade while it is moving, loose clothing may catch. Remove any rings or jewelry that could be seen on the blade as well. As a result, you shouldn't wear gloves that are too loose 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.

3. 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 also clamp a piece of wood to the side of the work that was cut off.

4. 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, anyone nearby may be struck by the shrapnel created by the blade or aluminum splintering off quickly. Before beginning to work on the aluminum workpiece, I strongly advise clamping it in place.

To prevent the blade from clogging with debris or catching on the aluminum, 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.

5. 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.

6. USE A VISE OR CLAMP

To keep the workpiece from sliding when cutting, always use a clamp or a vice. Additionally, it might assist in providing precise, clean, and straight cuts. 

CONCLUSION

We hope this post will be helpful to 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. Additionally, you can lower the risk of cutting aluminum by adhering to the safety measures listed above.