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Best Circular Saw Blade for Cutting Aluminum – Cut Metal as Butter

by James Antony | Last Updated: 15th July 2019

For many DIYers, cutting aluminum is integral in many home projects. This soft metal is used in many materials, from the roof to a bike frame. But cutting aluminum may seem intimidating at first. Having a circular saw blade should give you the confidence to pull off the task.

The circular saw is considered as one of the most versatile power tools around. It is versatile enough and powerful to perform any job. When paired with the right blade, it can cut through aluminum and other soft metal types with relative ease.

Below are five of the best circular saw blades that you can use for cutting aluminum.


Oshlun SBNF-140100 14-Inch 100 Tooth TCGBest Circular Saw Blade for Cutting Aluminum

Oshlun SBNF-140100 14-Inch 100 Tooth TCG - Best Circular Saw Blade for Cutting Aluminum

Oshlun SBNF-140100 14-Inch 100 Tooth TCG

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This non-ferrous cutting circular saw blade has a triple chip tooth configuration, enabling it to excel at cutting hard metals such as aluminum and other non-ferrous metals like copper and bronze. This also ensures a more efficient cut.

It has a pro-grade, precision quality carbide tip that lasts long. You should be able to use this circular saw blade for a long time. Moreover, the carbide tip results to noise-free cuts in almost all kinds of non-ferrous materials, including aluminum.

It comes with copper-plugged expansion slots for reduced noise and vibration. Heat vent is available for controlled heat operation. This blade has a maximum RPM of 4300.

  • This circular saw blade cuts nicely through aluminum and other types of materials like metal roofing sheets and cement backer board
  • It cuts cleanly and quickly without burring
  • This circular saw blade has a reasonable price compared to most circular saw blades
  • It does not easily get dull, too
  • Compatible with most metal cutting saws, this blade delivers no kickback when cutting
  • It also leaves no residue after cutting
  • This is arguable, pound for pound, the best circular saw blade for cutting aluminum
  • However, take note that this saw blade tends to wobble when cutting through an aluminum sheet
  • It is thus recommended that you use a proper clamping device with this blade
  • The use of coolant is also highly recommended when cutting non-ferrous materials

Concord Blades ACB1000T100HPBest Budget Circular Saw Blade

Concord Blades ACB1000T100HP - Best Budget Circular Saw Blade

Concord Blades ACB1000T100HP

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The Concord Blades ACB1000T100HP is made of hard titanium carbide. It can efficiently cut through aluminum and non-ferrous metals. It is also effective in slicing other materials like plastics, PVC, plexiglass, fiberglass, and acrylics.

It has a maximum RPM of 5350 and fits saws with a 5/8-inch arbor. The blade comes nicely packaged in a thick cardboard sleeve to protect its teeth. This is one of the best circular saw blades you can get at an affordable price.

  • The blade’s titanium carbide teeth can easily cut through aluminum and other non-ferrous metals
  • Its distinctive design allows it to deliver a superior cut
  • This beast is more than capable of cutting an aluminum pipe or bar without damaging itself
  • It is also able to handle other materials like wood
  • With its 10-inch diameter and 100 teeth count, the blade can achieve deep cuts rather quickly
  • It has a thin kerf of 3.2mm, unique TCG grid, and 5-degree hook all designed for a thin and smooth pro-grade cutting
  • The blade occasionally leaves a small burr, but this can be easily addressed with several strokes of a steel file
  • It has fine teeth, too, which makes the cutting rate a bit slow
  • It is also recommended that clamp is used to go with the miter saw

Freud Diablo D0648F Best Entry Level Circular Saw Blade

Freud Diablo D0648F - Best Entry Level Circular Saw Blade

Freud Diablo D0648F

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The Freud Diablo D0648F has a maximum RPM of 11,000 and an arbor of 5/8-inch. It can be utilized in any portable saw capable of accommodating a 6 and 1/2-inch blade.

This saw blade can cut through aluminum and other ferrous materials. It can do so quickly and accurately with cuts that are clean and burr-free. It is ideal for use in cutting steel pipes, steel sheets, and steel thuds. This is best used for mild steels that are less than 1/8 inch thick.

It features the TiCo hi-density carbide with titanium design for long life and clean finish. Its triple chip design ensures a longer cutting life.

  • The Freud Diablo D0648F cuts through aluminum and steel like butter
  • It does an excellent job of cutting finished aluminum
  • This ultra-sharp blade can also cut through most materials without kickback
  • It can fit in a standard 6 1/2 -inch circular saw
  • The blade dulls quickly, especially when used to cut aluminum and other metals
  • One way to prevent it from dulling fast is to lubricate it regularly



DEWALT DW9152 6-1/2-Inch 36 Tooth Saw Blade Best Value Circular Saw Blade

DEWALT DW9152 6-1/2-Inch 36 Tooth Saw Blade - Best Value Circular Saw Blade

DEWALT DW9152 6-1/2-Inch Saw Blade

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This DEWALT saw blade does not have the highest number of teeth in this list, yet it makes up for it with its material. The DEWALT DW9152 has teeth made of carbide, which adds extra strength for cutting through aluminum as if it is plywood.

With its carbide teeth, the blade is resistant to friction and temperature differences. A non-corrosive material, carbide also makes the blade ultra-durable and last for a long time. It has a thin kerf for fast and clean cuts.

  • You can get value for your money with this blade
  • It cuts evenly and cleanly
  • With just 36 teeth, it can also cut quicker than most of the saw blades in this list
  • When used in a cordless saw, the blade tends to spray aluminum fragments; thus, it is recommended that you use eye protection

Evolution Power Tools 12BLADEAL Aluminum Cutting Saw Blade Best Premium Circular Saw Blade

Evolution Power Tools 12BLADEAL Aluminum Cutting Saw Blade - Best Premium Circular Saw Blade

Evolution Power Tools 12BLADEAL

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This Evolution aluminum cutting saw blade is not the cheapest in the list, but you can be assured that you will get your money’s worth with it. This premium circular saw blade cuts quickly.

It leaves behind a workable finish sans heat, sparks, or burrs. You won’t have to wait for aluminum to cool down when you use this circular saw blade.

The blade features 80 carbide teeth that are not only strong but also durable enough to last longer than a blade made of abrasives. It can maintain its cutting quality and capacity throughout and save you money in the long run.

  • A real workhorse, the Evolution Power Tools 12BLADEAL has no problems cutting through aluminum
  • It cuts easily and quickly through aluminum and other non-ferrous materials
  • It leaves an edge with little burring and which looks like it was machined
  • This is not the cheapest circular saw blade around so expect to pay more per cut
  • It also puts out a lot of sparks so better be ready with your goggles
  • It is also not a quiet blade at all



TOMAX 12-Inch 100 Tooth TCG Aluminum Durable Saw Blade

TOMAX 12-Inch 100 Tooth TCG Aluminum - Durable Saw Blade

TOMAX 12-Inch 100 Tooth TCG Aluminum

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This 100-tooth blade is ideal for cutting aluminum, plastic, and other non-ferrous materials. The teeth are made of high-grade carbide and coated with electrophoretic material to minimize rusting and corrosion. A lifetime warranty backs it.

  • This blade has no problems slicing through aluminum
  • It cuts efficiently with cut material requiring no clean-up
  • It also does not jump or chatter, able to track straight through most materials
  • Plus, it shows no build up and tooth loss even after prolonged use
  • In short, this is an excellent blade that should last for a long time
  • It tends to wobble from side to side
  • To prevent this from happening, ensure that the blade is mounted correctly

Best Circular Saw Blade for Cutting Aluminum

Best Circular Saw Blade for Cutting Aluminum – Buyer’s Guide


Contents:


What is a circular saw blade?

A circular saw blade is around and flat blade consisting of teeth. Fitted to a circular saw, it can cut through various materials using a spinning motion.

A circular saw blade is versatile. It can be used on other power tools like miter saws, table saws, radial saws, and cut-off saws.

But not all circular saw blades are created the same. Others are simply designed for chopping wood while others are powerful enough to cut through aluminum, plastic, and metals.



What are the types of circular saw blade?

There are various types of circular saw blades, each designed to cut different materials. These include:


Which of those types of blade do you use to cut aluminum?

A metal cutting blade, which comes in various sizes and materials like carbide and steel, can cut through aluminum. It can also be used in cutting other materials like vinyl, hardwood, softwood, and plexiglass.



What are the things to consider in buying a circular saw blade for cutting aluminum?


Freud Diablo D0648F - Best Entry Level Circular Saw Blade

Why is the blade diameter critical?

The blade diameter is critical because one, it determines the depth of cut, and two, the speed of the saw, which is expressed in rotation per minute (rpm).

The blade diameter would depend on the saw with which it will be paired with. Most circular saws can accommodate a 7 and 1/8-inch diameter blade. This can give a cutting depth of 2.25 inches. Table and miter saws, on the other hand, require blades with 10 to 12-inch diameter.



How important is the number of teeth?

The rule of thumb is simple: the more teeth that a blade has, the better it is at making precise cuts. It is for this reason that blades with more teeth are best used for cutting aluminum. Laminate finished with aluminum oxide, for instance, is more likely to chip if it is cut with a blade with few teeth. The blade will also dull faster due to the material it was used against.

Circular saw blades typically have teeth ranging from 24 to 100. If you can get a blade with 100 teeth, the better as it can result in a clean and more efficient cut, however, keep in mind that there is also a downside to using a blade with a high number of teeth—it can slow down the cutting process.

On the other hand, circular saw blade with few teeth may be able to cut through aluminum faster than one with more teeth. However, you may be sacrificing the quality of the cut as the blade would likely remove more material.


How about the teeth material?

The teeth material will determine how effective or efficient the blade is in cutting through an item. The rule of thumb is that the material of the teeth or blade should be much stronger than the material you want to cut.



What are the materials used in saw blades?

As you may have learned after reading the reviews above, carbide is a popular material integrated into circular saw blades. It is a hard material compound that resists wear and temperature differences. It is highly durable and unalterable. This non-corrosive material is also resistant to friction.

It is common for carbide to be integrated with another hard material like tungsten, resulting in a super metal alloy. Tungsten carbide blades are known for their clean and precise cuts of aluminum and other non-ferrous metals.

There are also blades made of diamond, which is one of the hardest materials on earth. Those blades are used for cutting asphalt, concrete, and other abrasive materials.


Evolution Power Tools 12BLADEAL Aluminum Cutting Saw Blade - Best Premium Circular Saw Blade

How to choose a blade for your saw?

Aside from the features of the blade, you must also consider the specifications of your saw. The capability of your saw should be compatible with the blade diameter and type.

Generally speaking, handheld circular saws accept blades that have a diameter of between 4 ½ inches and 7 ¼ inches. Most of these blades are carbide-tipped.

If you have a tile saw, you should look for blades that are 7 to 10 inches in diameter. Compound miter saws and table saws generally use blades that are 10 to 12 inches in diameter. These are also carbide-tipped.

You should also check the size of the hole in the middle of the blade, or the arbor hole. It should fit the shaft of your saw. Finally, take note of the RPM rating of the blade and ensure that it is compatible with the saw you intend to use it with.



What is kerf?

Kerf refers to the thickness of the blade. Circular saws are capable of accommodating blades of various thicknesses. For cutting aluminum, it is better to opt for a thinner blade as it is usually sharper. It can move quicker and remove less material with each cut.


What is arbor?

This is the shaft or spindle where the blade is mounted to. It can come in various sizes depending on the style and size of the saw. The most common arbor hole size is 5/8-inches for blades sized from 7-1/4 inches to 10 inches. As a general rule, the larger the diameter of the saw blade, the larger the arbor hole size is.



Can a wood blade cut aluminum?

Yes, it is possible to cut aluminum using a wood saw if it has carbide-tipped blades. Wood saw with fine-teeth blade can cut through aluminum with a thickness of not more than a quarter of an inch.


Can a hacksaw cut aluminum?

A hacksaw is a tool that’s commonly used for cutting various materials around the house. You may be surprised to learn that it is also capable of cutting aluminum and other soft metals. If you have a hacksaw at home, you can use a blade with 32 teeth to be able to cut soft metals like aluminum.



How many teeth does it take to cut aluminum?

This would depend on the blade material and the type of saw to be used. As mentioned earlier, a hacksaw with 32 teeth should be able to cut aluminum, although not at the fastest pace.

DEWALT DW9152 6-1/2-Inch 36 Tooth Saw Blade - Best Value Circular Saw Blade

The DEWALT DW9152 circular saw blade is one proof that a circular blade does not need a lot of teeth to be able to cut through aluminum. Made of carbide, it has enough power to slice through aluminum.


Can you cut aluminum with a carbide saw blade?

Yes, definitely! A saw with carbide-tipped blades will have an easy time slicing through non-ferrous metals such as aluminum, brass, copper, and lead. Durability is another advantage of carbide saw blades as these can last longer than regular steel ones.


What is a kickback?

This is one of the most common and dreaded accidents that can happen while using a circular saw. It occurs when the blade binds on the material and either throws the material or saw itself back at the operator.

Kickback may also occur when cutting aluminum as the cut-off pieces are thrown off by the circular saw. This makes wearing of protective clothing important when cutting aluminum and other soft metals.


How do I know that a blade needs to be replaced?

Replacing or changing a circular saw blade is important because a dull blade will not be able to cut through the aluminum efficiently or quickly as you want.

A dull blade is easy to spot. If you push the circular saw blade through the aluminum and it doesn’t go as smoothly as you want, then it is likely because of the blade.



How to take care of the circular saw blade?

Regardless of the blade you choose, it is essential to take good care of it so that you can make your projects safely and efficiently.

One of the best ways to protect a circular saw blade is to clean it regularly. The blade is prone to contamination with pieces of dirt, dust, and sap clinging to it. These can add more friction if not removed, making it likely for the blade to overheat during usage. Moreover, dirty blades tend to dull quicker. You can use a brass-bristled brush or plastic cleaners in cleaning circular saw blades.

Aside from regularly cleaning saw blades, you should periodically sharpen it. The teeth should also be protected from chipping. This can be accomplished by avoiding contact with the teeth while the blade is in storage.


Best Circular Saw Blade for Cutting Aluminum – Conclusion

The use of a power tool is perhaps the most cost-effective way of cutting aluminum. Circular saws are not only relatively cheap but easy to use for a typical DIYer. But there are other more advanced ways of cutting the soft metal like the use of lasers, which can cut light to medium aluminum gauges. However, it can be costly, aside from the challenge of dissipating the heat.

Did you like our Best Circular Saw Blade for Cutting Aluminum review? Please comment and don’t forget to check our other reviews – Best Hole Saw for Metal review could be interesting for you!

And don’t forget about circular saw safety rules

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