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Cutting Aluminum with a Miter Saw: The Basics

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Written By John Gibbs

 

 

 

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Aluminum is a versatile metal that can be used for a variety of applications. It is lightweight yet strong, making it ideal for use in construction and other industries. When it comes to cutting aluminum, a miter saw is the best tool for the job.

In this article, we will be discussing how to cut aluminum with a miter saw. We will go over what kind of saw to use, the different types of blades, and how to set up your saw for success. By the end of this article, you should feel confident in your ability to cut aluminum like a pro!

Can You Cut Aluminum with a Miter Saw?
Yes, you can aluminum-cutting miter saw, but there are a few things you need to keep in mind to do it safely and effectively. When cutting aluminum with a miter saw, it’s important to use a blade that’s designed for the material. Make sure you’re using a disk with plenty of teeth (at least 60) and that the teeth are sharp. A dull blade will cause the aluminum to tear and can also lead to a dangerous kickback.

Which Blades Do You Need to Cut Aluminum?

Cutting aluminum can be tricky because the material is soft and easily damaged. That’s why it’s important to use the right type of saw blade. The wrong disk can cause the material to chip, crack, or even break.

There are two main types of blades that are suitable for cutting aluminum: carbide-tipped and diamond-tipped. Carbide-tipped is the most common type of blade used for cutting aluminum. They’re made from a hard material that can withstand the heat generated by the process.

miter saw

Diamond-tipped is made from a harder material than carbide-tipped blades, so they can stay sharp for longer. However, they’re also more expensive.

When choosing a disk, it’s important to consider the thickness of the aluminum you’ll be cutting. Thin sheets can be cut with either type of blade, but thicker sheets will require a diamond-tipped.

How Do You Cut Aluminum with a Miter Saw?

A miter saw is a versatile tool that can be used to make clean, precise cuts in a variety of materials, including aluminum.

When working with a miter saw blade for aluminum, it is important to use one that is designed specifically for cutting this metal. An all-purpose wood-cutting will not work as well on aluminum and can dull quickly. A blade with carbide teeth is a good option.

It is also important to use a lower speed. A speed that is too high can cause the aluminum to melt and stick to the blade, making it difficult to finish the cut.

When cutting aluminum, it is important to go slow and steady. A fast, jerky motion can cause the disk to bind and potentially break.

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Cutting Aluminum with a Miter Saw & Wood Blade

Most wood blades have 24 to 80 teeth, making them ideal for cutting aluminum. The number of teeth will determine how smooth the cut is. A disk with more teeth will create a smoother cut, while a blade with fewer teeth will be more aggressive and create a rougher cut. If you are cutting aluminum, you will want to use a blade with more than 10 teeth for each diameter inch. For a 12-inch miter saw, use a 120 teeth blad.

When working, it is important to use a disk that is designed for cutting non-ferrous metals. They have carbide teeth that are harder than aluminum and will stay sharp longer. They also have a special grade of carbide that is designed for cutting this metal.

Cutting Aluminum with a Miter Saw & Wood Blade

It is also important to use a lubricant. This will help to cool the blade and prevent the aluminum from sticking to it. A water-based lubricant is a good choice. You can also use WD-40 or a similar product.

Can I Cut Aluminum with a Chop Saw?

Yes, you can! Here’s a quick guide on how to do it.

  1. You’ll need to make sure that your chop saw is set up properly.
  2. You’ll need to select the right blade for cutting aluminum. A general-purpose will work, but if you have the option, choose a disk that’s specifically designed for cutting aluminum. This will help to ensure a clean, precise cut.
  3. Place the aluminum piece on the saw’s table and align it with the blade. Slowly start the saw and let it do its work. Keep your hands away from the disk, and be careful not to put too much pressure on the piece you’re cutting.

Electric chop saw

Cutting Aluminum With Circular Saw

If you’re working with aluminum, you know that it’s a soft metal that is easy to cut. But what if you don’t have a saw that is specifically designed for working with this metal? Can you use a regular circular saw?

The answer is yes. However, there are a few things that you need to keep in mind in order to get the best results.

  1. You need to make sure that the blade on your saw is designed for cutting aluminum. If it’s not, you run the risk of the disk getting dull quickly or even breaking.
  2. You need to use a slower speed. This will help to prevent the blade from overheating and breaking.
  3. You need to be very careful. It’s easy to create sparks when cutting aluminum, so you need to be sure that you’re in a well-ventilated area and that you’re wearing proper safety gear, including gloves and a face mask.

Saws for Cutting Aluminum

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The Best Blades for Cutting Aluminum with a Miter Saw

If you are looking for the best miter saw disk for cutting aluminum, you have come to the right place. Below we will show you some of the best blades for working with this metal.

1. WEN BL1200 Carbide-Tipped Professional Woodworking Saw Blade

Product detail

  • Material: Carbide
  • Brand: WEN
  • Style: Standard
  • Compatible Material: Wood

Whether you’re a professional woodworker or a hobbyist, having a dependable and accurate saw blade is essential for precise cuts. The WEN 12-Inch Professional is a great option for anyone in need of a high-quality, durable saw disk.

With its machine-cut carbide-tipped teeth, it can easily cut through tougher woods such as oak and cherry, as well as softwoods like pine and poplar. The 1-inch arbor makes it compatible with most 12-inch miter saws, job site saws, and table saws on the market.

At just 1/10 of an inch thick, this lightweight and ultra-thin is designed for maximum efficiency and produces little to no sawdust. Whether you’re working on a big project or a small one, the WEN 12-Inch Professional Woodworking Saw Blade is a great option for anyone in need of a reliable and powerful.

PROS:
  • Reliable and accurate
  • 2-year warranty
  • Quickly and easily slice through even the hardest of woods
CONS:
  • Some users have reported that the blade dulls quickly after extended use.
  • The disk may not be compatible with all types of miter saws.

2. Makita A-93681 Micro Polished Mitersaw Blade

Product detail

  • Material: Carbide
  • Brand: Makita
  • Item Dimensions: 12 x 11.8 x 0.2 inches
  • Color: Silver
  • Number of Teeth: 80
  • Style Miter Saw: Micro-Polished

The Makita A-93681 Micro Polished Mitersaw Blade is one of the best saw blades on the market. It is made with micro-grain carbide teeth that are honed with up to 600 grit for a mirror finish.

The saw disk has an ultra-thin kerf of .091″ and a 5-degree hook angle. It is ideal for cutting hardwood, softwood, and plywood. It comes with a .071 plate thickness for fine crosscutting.

PROS:
  • Micro-grain carbide teeth for a mirror finish
  • Steel saw plates are fully hardened and expertly hand tensioned
  • Ultra-thin kerf of .091″
CONS:
  • None

3. TOMAX 10-Inch 80 Tooth TCG Aluminum and Non-Ferrous Metal Saw Blade

Product detail

  • Material: Carbide
  • Brand: TOMAX
  • Number of Teeth: 80
  • Style: Table Saw
  • Compatible Material: Aluminum, Metal

Are you looking for an ideal saw blade for cutting applications in aluminum, plastics, copper, brass, and other non-ferrous metals? If so, the TOMAX 10-Inch 80 Tooth TCG Aluminum and Non-Ferrous Metal Saw Blade is a great option to consider.

It features a hardened steel body for increased durability and longevity, as well as laser-cut anti-vibration technology to reduce noise and extend cutting life. Additionally, the TOMAX 10-Inch 80 Tooth TCG Aluminum and Non-Ferrous Metal Saw Blade is designed to provide a clean, neat cut with virtually no heat, burrs, or sparks.

PROS:
  • Hardened steel body for increased durability
  • Laser-cut anti-vibration technology for reduced noise
  • Provides a clean, neat cut with virtually no heat, burrs, or sparks
CONS:
  • It may not be suitable for use with all materials

4. Evolution 14 Inch Metal Cutting Chop Saw

Product detail

  • Brand: Evolution
  • Blade Material: Stainless Steel
  • Surface Recommendation: Wood, Metal
  • Power Source: Corded Electric
  • Special Feature: Quick Release Vice

As a welder, having a powerful and accurate chop saw is essential for making quick, clean cuts. The Evolution 14 Inch Metal Cutting Chop Saw has a 15 Amp motor and a pressed steel base, making it both powerful and portable.

The included premium tungsten carbide-tipped blade is designed for cutting mild steel and significantly outperforms abrasives. The saw also features a cast steel vise and fence with a quick-release mechanism, making it easy to clamp and cut metal tubing quickly and safely.

With the Evolution 14 Inch Metal Cutting Chop Saw, you can make clean, accurate cuts on metal tubing quickly and easily without having to worry about sparks or messy cleanup.

PROS:
  • Powerful 15 Amp motor
  • Pressed steel base for portability
  • Tungsten carbide-tipped blade for clean, accurate cuts
  • Cast steel vise and fence for quick, safe cutting
  • Chip deflector to reduce cleanup time
CONS:
  • The blade may need to be replaced after extended use

5. Evolution Power Tools 7-1/4-Inch TCT Multipurpose Cutting Chop Saw

Product detail

  • Brand Evolution: Power Tools
  • Blade Material: High Speed Steel
  • Surface Recommendation: Wood, Aluminum, Plastic
  • Power Source: Corded Electric

The Evolution Power Tools 7-1/4-Inch TCT Multipurpose Cutting Chop Saw is a versatile and powerful saw that is perfect for a variety of applications. This saw is capable of cutting through steel, aluminum, wood with nails in it, and even plastic.

The blade installation is very straightforward, and the saw comes with clear instructions. This saw is also very easy to use, and it cuts through material very smoothly.

The only downside to this saw is that it is not suitable for cutting thicker materials. However, for home use, this saw is more than adequate. It is a great saw for home projects and is sure to make any job easier.

PROS:
  • Very versatile
  • Can cut through a variety of materials
  • Easy to set up and use
  • Cuts smoothly
CONS:
  • Not suitable for cutting thicker materials

6. Genesis GCOT335 High-Speed Cutoff Tool

Product detail

  • Brand: Genesis
  • Blade Material: High Speed Steel
  • Surface Recommendation: Metal
  • Power Source: AC

The Genesis GCOT335 High-Speed Cutoff Tool is an excellent choice for anyone looking for a powerful and easy-to-use cutting tool. With a 3.5-amp motor and a speed of 24,000 RPM, this tool can easily cut through a variety of materials, making it an essential tool for auto-body repair.

The safety switch prevents accidental starting, while the tool-free adjustable guard release allows for quick and easy access to the disc. The included arbor wrench and hex key make changing the disc a breeze, and the 3-in. cutoff disc ensures that you can get started on your projects right away.

The lightweight design and standard 3-in. cutoff disc compatibility make the Genesis GCOT335 an excellent choice for a variety of applications.

PROS:
  • Powerful 3.5-amp motor
  • Compatible with standard 3-in. cutoff discs
  • Lightweight design for easy maneuverability
CONS:
  • The on/off button can be tricky to use

Tips for Cutting Aluminum with a Miter Saw

Here are some tips to help you get the best results when cutting aluminum with a miter saw:

Secure the workpiece

Secure the workpiece, so it doesn’t move while you’re cutting. You can do this by clamping it to a worktable or using a vise.

Use a Fine Blade

A dull disc will cause the aluminum to tears. Make sure you’re using a sharp, carbide-tipped design for working with this metal. You should also use it with a high tooth count for a smooth cut.

Fine Blade

Wear PPE

When working with any type of saw, it is important to wear the proper Personal Protective Equipment (PPE). This includes eye protection, gloves, and a dust mask.

Construction worker cutting metal

Cut-Off Piece

Another thing to consider is the cut-off piece. When the cut-off piece is long, it can whip around and hit you or someone else in the face. If the piece is short, it can be pulled into the blade and cause kickback. To avoid these hazards, always use a push stick or other device to keep the cut-off piece didn’t bother you.

Use Cutting Oil

When cutting aluminum with a miter saw, it is important to use cutting oil. This will help to lubricate the disc and prevent it from overheating. Apply the cutting oil to the blade before making each cut.

Conclusion

If you’re looking to cut aluminum, a miter saw is a great tool to use. In this article, we covered the basics of how to work with this metal, including what type of saw blade to use and how to set up your cuts. With a little practice, you’ll be able to cut aluminum like a pro.

Do you have any tips for cutting aluminum with a miter saw? Let us know in the comments below.

Thanks for reading!

FAQ

Do I need a special saw blade to cut aluminum?

When cutting aluminum with a saw, it’s important to use the right type of blade to avoid damaging the material. The best type of blade to use is a carbide-tipped with a fine tooth count. This will help to prevent the disc from catching on the aluminum and ensure a smooth, clean cut.

How thick aluminum can you cut with a circular saw?

Most circular saws can handle aluminum that is between 0.5 and 6 in thick. If you are cutting something that is thicker than that, you will need to use a different type of saw.

Can you cut aluminum with a diamond blade?

If you’re looking to do some quick and easy cutting of aluminum, then a diamond blade is definitely the way to go.

One thing to keep in mind, however, is that it is also a relatively brittle material, meaning that it can easily shatter if you’re not careful. So, when cutting aluminum, be sure to use a slower speed and use a sharp blade to avoid any potential accidents.

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About John Gibbs

Hello everyone! My name is John Gibbs. I am 60 years old and have been in the family construction business all my adult life. Construction is not only my profession but also my passion. I know everything about building and repair materials, tools, advanced methods, techniques, and approaches. I will share the same knowledge with you in my articles.

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