Can an electric saw cut metal?

Electric saws are powerful tools that can cut through a variety of materials. Many DIYers and professionals wonder whether an electric saw can cut metal as easily as wood. The quick answer is yes, electric saws can cut metal under the right conditions. However, cutting metal requires specialized blades and techniques compared to cutting wood.

What Types of Metal Can an Electric Saw Cut?

Electric saws are capable of cutting through thin sheets of mild steel, aluminum, copper, brass and iron. With the proper blade, electric saws can cut through metal up to 1/8 inch thick. Thicker metals over 1/8 inch may be possible to cut, but difficult and time consuming.

Some examples of mild metals that can be cut with an electric saw include:

• Sheet metal
• Aluminum siding
• Duct work
• Steel studs
• Corrugated roofing
• Metal pipes under 1 inch diameter

Heavier gauge metals and alloys such as stainless steel may damage saw blades not designed for these materials. Always check the saw blade specifications before attempting to cut thick or heavy duty metal.

Choosing the Right Blade

Cutting metal requires a specific metal cutting blade rather than a wood or multi-purpose blade. Abrasive metal cutoff wheels are commonly used with compact circular saws up to 7 inches. Larger circular saws use composite friction metal blades up to 12 inches. Jigsaws use bi-metal blades designed for non-ferrous metals. The optimal metal cutting blade depends on the saw type and thickness of the metal being cut.

Here are the blade characteristics to look for:

• Abrasive cutoff wheel for compact circular saws
• Composite friction blade for full-size circular saws
• Bi-metal jigsaw blade
• Minimum 24 teeth
• Triple chip tooth grind
• Positive rake angle teeth

The blade must be specifically made for cutting metal. Using a wood blade will result in immediate blade damage or dangerous kickback when contacting metal.

Cutting Technique

Proper technique is crucial when cutting metal with a circular saw or jigsaw. Here are some tips:

• Use light and steady pressure allowing the blade to gradually cut through the metal
• Avoid forcing the blade which can cause binding, kickback or broken teeth
• Cut slowly to avoid overheating the blade
• Support the metal on both sides of the cut to prevent vibration
• Use lubricating coolant to prolong blade life
• Let the blade do the work, don’t force the cut

Rushing through cuts and forcing the saw will lead to inaccurate cuts and damaged blades. Take your time and let the proper blade do the work.

Circular Saw Cutting Tips

Standard 7-1/4 inch circular saws with a friction metal blade are adept at cutting thin sheet metal. Here are some best practices when using a circular saw:

• Install a clean, sharp friction blade designed for metal cutting
• Adjust the blade depth just above the thickness of the metal
• Hold the saw firmly with both hands to control cutting pressure
• Make guide marks for straight cuts using a square
• Use a clamped straightedge to follow for straight cuts
• Support the metal on both sides near the cut line
• Use steady, even pressure when cutting
• Allow the saw to gradually cut through the metal
• Use lubricating coolant to prevent blade sticking
• Don’t force the saw when cutting, go slow

With the proper blade and technique, a circular saw is effective for cutting metal sheets less than 1/8 inch thick.

Jigsaw Cutting Tips

Jigsaws are well-suited for making curved cuts in thin metal sheets. Here are some recommendations when cutting metal with a jigsaw:

• Install a bi-metal jigsaw blade made for non-ferrous metal
• Adjust orbital action to low for increased control
• Secure the metal sheet with clamps to prevent vibration
• Go slow on curves to avoid overheating and binding the blade
• Support metal near the cut line on both sides
• Release blade pressure frequently to cool the blade
• Use steady, light pressure letting the blade cut
• Apply cutting lubricant to the blade periodically
• Allow the jigsaw to do the cutting, don’t force it
• Pause occasionally to prevent motor overheating

Jigsaws allow you to make precise curved cuts through thin metal sheets. Take it slow and let the blade designed for metal do its job.

Use Proper Safety Gear

Safety equipment is essential when using power saws to cut metal. Here is the minimum safety gear required:

• Eye protection – Full seal safety glasses at a minimum
• Hearing protection – Use earplugs or muffs
• Work gloves – Leather gloves to protect hands
• Long sleeve shirt
• Full length pants – Avoid shorts or loose clothing
• Closed toe shoes – Prevent foot injuries
• Dust mask – Prevent inhaling metal fragments

Sawing metal can generate significant debris and shards. Dress appropriately and use eye, hearing and respiratory protection.

Is an Angle Grinder Better for Cutting Metal?

Angle grinders are actually the optimal power tool for cutting thicker metal. While saws can manage thin sheets, angle grinders equipped with abrasive cutoff wheels are purpose-built for slicing metal.

Reasons an angle grinder is superior for metal cutting:

• Generates far less heat and friction when cutting
• Easily cuts thicker metal up to 1⁄4 inch and larger
• Cuts quickly through steel, stainless, cast iron and alloys
• Wide range of inexpensive cutoff wheel sizes and styles
• Less binding in the cut compared to a reciprocating saw
• Easier to control cutting pressure

Angle grinders do create substantial sparks and debris requiring even more protection. But the cutting ability of an angle grinder goes well beyond a typical electric saw when working with metal.

Best Uses for Cutting Metal with an Electric Saw

While capable of cutting thin metal sheets in a pinch, saws are not optimal for intensive metal fabrication. Here are the best uses for occasional metal cutting with an electric saw:

• Slicing sheet metal less than 1/8 inch thick
• Cutting duct work and small pipes for HVAC projects
• Removing rusted old sheet metal and roofing
• Cutting aluminum siding and trim for exterior renovations
• Removing steel studs in demolition projects
• Trimming corrugated tin for sheds and outbuildings
• Sectioning thin wall square tubing and pipe

For lightweight metals under 1/8 inch, saws allow reasonable control and straight cuts. Their portability also allows making cuts on installed metal materials.

Disadvantages of Cutting Thick Metal with an Electric Saw

While electric saws can manage thin gauge metals in a pinch, some disadvantages quickly arise when cutting thick materials:

• High potential for binding – Especially reciprocating saws
• Blade overheating and rapid wear
• Excessive blade deflection – Reduces cutting accuracy
• Lower control and straight line cutting ability
• Higher vibration and operator fatigue
• Slow process requiring multiple passes
• Increased potential for kickback injuries

Saws lack the power, torque and rigidity for cleanly slicing thicker hard metals. Attempting to cut heavy gauge metal can be frustrating and dangerous.

Conclusion

While electric saws are mainly designed for cutting wood, they can cut thin sheets of metal in a pinch. The key is using blades specifically designed for cutting mild steel, aluminum and other metals. With the proper blade and careful technique, compact circular saws and jigsaws allow reasonable control when cutting thin gauge metals under 1/8 inch thick.

However, intensive metal fabrication is better accomplished with tools specifically engineered for cutting thick heavy metals, rather than overworking an electric saw. Angle grinders and abrasive chop saws are purpose-built for powering through steel, cast iron, stainless and alloy metals quickly and efficiently.

For occasional light duty metal cutting, electric saws can get the job done. But when it comes to frequent heavy duty metalwork, choose equipment designed for the material and thickness being cut. This ensures optimal results and safety when working with metal.