What are The Different Types Of Saw Blades For Metal

Choosing the right saw blade is critical for success in metalworking, whether you're using a cold saw, band saw, or another cutting machine. The correct blade ensures efficient cutting, extends blade life, and, most importantly, enhances safety.

To help you navigate the choices, we've compiled a list of the top 5 saw blade types for metalworking, detailing their construction, benefits, and ideal applications so you'll never second-guess your selection again.

Types Of Saw Blades For Metal

1. Carbon Hardback Saw Blades

For general-purpose metal cutting, carbon hardback saw blades are the best choice. Each blade is expertly machined from a single piece of hardened, high-carbon steel, ensuring that both the band and teeth are incredibly durable. This design, combined with a spring-tempered backing (RC 43-47 for hardness) and super-hard teeth (RC 64-66), provides the extra stability needed for consistently accurate cutting on a wide variety of materials.

Ideal For: Utility cutting and intensive production setups, especially for continuous, all-day use. They are well-suited for a variety of materials due to their rigid design.

Compatible Materials: Aluminum, carbon steel, graphite, bronze, plastics, copper, mild steel, and various non-ferrous metals.

Carbon Hardback Saw Blade: Benefits

• Cost-Effective: Often a more economical choice for general cutting.
• Resists Back Edge Swaging: Their rigidity helps prevent the blade's back edge from deforming.
• Prevents Scoring: Provides cleaner cuts without scoring the material.
• Higher Feed Pressures: Can withstand greater feed pressure for faster cutting.
• Higher Cut Rates: Leads to more efficient and quicker material removal.

2. Carbon Flexback Saw Blades

Also made of carbon steel, Carbon Flexback saw blades feature a flexible blade body, distinguishing them from their rigid hardback counterparts. These blades are designed for cost-effective, all-purpose cutting and are remarkably robust, even at higher speeds, due to their flexible nature.

Ideal For: Straight and contour cutting, particularly in workshops, small foundries, and maintenance shops where versatility and durability are key.

Compatible Materials: Composition boards, low alloy metals, non-ferrous metals (like lead, wood, brass, aluminum), light section steels, and plastics.

Construction: Made from a single piece of carbon steel, featuring a hardened tooth edge (RC 64–66) for durability and a spring-tempered back (RC 31–37) for flexibility.

Carbon Flexback Saw Blade: Benefits

• Low Price: An economical choice for versatile cutting needs.
• Lengthened Fatigue Life: The flexible back reduces stress on the blade, leading to fewer fractures and extended operational life.
• Reduced Back Stress: The ability of the blade back to flex significantly lowers the risk of breaks.
• Blade Toughness at High Temperatures: While their toughness decreases around 300°F, they maintain good performance within their operational range.

3. Bi-Metal (Matrix) Saw Blades

The term "bi-metal" describes the unique material construction of these utility blades. A bi-metal blade features a flexible spring steel body with high-speed steel (HSS) teeth, strongly welded together. High-speed steel commonly includes 8% Cobalt for its exceptional wear properties and heat resistance.

Ideal For: General metal cutting applications where durability and consistent performance are required, especially when cutting tougher alloys that carbon blades might struggle with. They are a significant upgrade from carbon blades for many industrial uses.

Construction: A high-speed steel (HSS) edge material is precisely welded to the tips of the teeth, supported by a spring steel backing.

Bi-Metal (Matrix) Saw Blade: Benefits

• Superior Fatigue Endurance: The spring steel body allows for flexing without breaking, a common issue with solid carbon blades, leading to a much longer working life.
• Resistant to Back Edge Swaging: Maintains structural integrity under tension.
• Straighter Cuts: Operates effectively under higher band tension compared to carbon steel blades, resulting in more accurate and straighter cuts.
• Enhanced Heat Resistance: Blade toughness decreases at approximately 1300°F, indicating much higher heat resistance than carbon blades, allowing for more aggressive cutting.

4. Carbide-Tipped Saw Blades

Carbide-tipped saw blades represent a leap in cutting technology, specifically engineered for cutting off various types of tough metals. These blades feature a high-strength alloy steel backing onto which individual tungsten carbide tips are welded at the tooth points. The use of tungsten carbide, a material known for its extreme hardness and heat resistance, means these blades retain their sharpness significantly longer than HSS or carbon blades.

Ideal For: Heavy-duty cutting tasks across various industries, especially for materials that are too hard or abrasive for bi-metal blades. They are frequently utilized in mechanical and related sectors.

Compatible Materials: Steel, cast iron, copper, bronze, non-ferrous metals, aluminum alloys, and many other challenging materials.

Construction: High-strength alloy backing with individually welded tungsten carbide tooth points. They often feature a "triple chip" grind configuration, where every other tooth has a double bevel rather than being straight, optimizing chip removal and cutting performance.

Carbide-Tipped Saw Blade: Benefits

• Cuts Tougher Substances: Excels at cutting hardened steels and highly abrasive materials.
• Most Effective Finish: Provides a superior finish, particularly beneficial for non-ferrous applications where clean cuts are paramount.
• Greater Power: Allows for more aggressive cutting with higher feed rates.
• Exceptional Heat Resistance: Maintains performance even under high cutting temperatures, prolonging blade life.
• Eliminates Tooth Set Collapse: The robust carbide tips resist wear and binding, preventing the common issue of tooth set collapse that can occur with less durable blades.

5. Grit Edge Saw Blades

Grit Edge saw blades are a specialized category, designed for cutting extremely tough, abrasive, or "sticky" materials that would rapidly dull or clog conventional toothed blades. Instead of distinct teeth, these blades feature diamond or tungsten carbide grits bonded directly to the blade's edge.

Ideal For: Cutting very hard, abrasive, or non-ferrous sticky materials that are challenging for traditional toothed blades.

Compatible Materials: Ceramics, fiberglass, carbon fiber, composites, hardened steel, cast iron, masonry, and highly abrasive materials where traditional teeth would fail. For sticky materials like aluminum, these blades can feature either straight edges or "gullet" edges to aid in chip clearance.

Grit Options: Available in medium or coarse grit, depending on the desired finish and material removal rate. Coarse grit removes more material quickly, while medium grit provides a finer finish.

Grit Edge Saw Blade: Benefits

• Cuts Extremely Tough/Abrasive Material: Excels where conventional teeth cannot.
• Faster Blade Speeds: Can often be run at higher blade speeds due to the lack of traditional teeth and their abrasive cutting action.
• No Tooth Chipping/Breaking: Eliminates issues related to tooth loss common with other blade types.
• Versatility: Can cut materials with irregular shapes or variations in hardness.

Quick Comparison: Metal Saw Blade Types

For a quick reference, here's a summary of the different types of saw blades for metal and their primary uses:

Conclusion

Regardless of the type of metal-cutting project you're working on, whether fabricating custom parts from aluminum sheet stock or simply making repairs around your home, having the right saw blade for metal will make all the difference in ensuring your job is completed safely, efficiently, and correctly every time. By understanding the unique construction and benefits of carbon hardback, carbon flexback, bi-metal, carbide-tipped, and grit edge saw blades, you can confidently select the perfect blade to achieve professional results.