You use different saws to cut metal. A hacksaw is great for small jobs. A band saw works well in a shop. For tough cuts, you might choose an abrasive chop saw for metal. The right tool makes cutting metal much easier and safer. We will look at all the types of saws for metal so you can pick the best saw for cutting metal for your task.
Choosing the Right Tool for Metal Cutting
Cutting metal requires special tools. Wood saws use sharp teeth to slice through wood fibers. Metal, however, is hard and dense. It needs tools that can either shear the metal or grind it away slowly. Picking the wrong saw can break the blade, hurt you, or just not cut through the material.
We need to match the saw to the metal type, thickness, and the shape of the cut (straight, curved, or angle). Finding the best saw for cutting metal depends on what you are working on.
Hand Tools: Simple and Effective for Small Jobs
For quick fixes or small projects, hand tools are often the first choice. They are cheap and do not need electricity.
The Mighty Hacksaw
The hacksaw is the most common hand tool for cutting metal. It is simple, like a small frame holding a thin blade.
How a Hacksaw Works
A hacksaw uses a fine-toothed blade. You push and pull the saw back and forth. The teeth on the blade remove tiny bits of metal with each stroke. This process is called abrasion.
Blade Selection is Key
The most important part of using a hacksaw is the blade. Blades are rated by Teeth Per Inch (TPI).
- High TPI (24 to 32 TPI): Use these for very thin metal, like sheet metal or tubing. More teeth mean smaller chips and a smoother cut.
- Medium TPI (18 to 24 TPI): Good for medium-thickness metal like rods or angle iron.
- Low TPI (14 to 18 TPI): Use these for thick, solid metal bars. Fewer teeth help prevent the blade from getting stuck in the deep material.
Always choose a blade where at least three teeth touch the metal at all times. This stops the teeth from catching and breaking.
Power Saws for Faster Metal Cutting
When you have a lot of cutting to do, or the metal is thick, you need a power tool. Power metal cutting saws turn hard work into fast jobs.
Reciprocating Saws: The Versatile Cutter
A reciprocating saw, often called a Sawzall (a brand name), is famous for demolition. But it is also a very capable metal cutting saw.
Using a Reciprocating Saw for Metal
These saws move the blade back and forth very fast. They are great for cutting pipe or rebar right where it sits. You don’t need to take the piece apart first.
To cut metal well with a reciprocating saw, you must use a specific blade. Metal-cutting blades are shorter and have high TPI. Use slow speeds for cutting thick metal. Fast speeds generate too much heat and ruin the blade quickly.
Pros of Reciprocating Saws for Metal:
- Very portable.
- Good for cutting in tight spots.
- Can handle curved or awkward cuts well.
Cons:
- The fast action can cause strong vibrations.
- Cuts are often rougher than those from a band saw for cutting metal.
Circular Saws for Metal Cutting
Can you use a circular saw for cutting metal? Yes, but you need a special one. A standard wood-cutting circular saw will fail instantly.
Dry Cut Metal Saws
Modern specialized circular saws are designed specifically for metal. These are often called “dry-cut saws.” They spin a carbide-tipped blade at a much lower RPM (revolutions per minute) than wood saws.
These blades cut metal like a milling machine cuts wood. The cut is cool, clean, and leaves very little burr (sharp edge). They are excellent for cutting steel studs, tubing, and flashing.
Abrasive Chop Saws: The Shop Workhorse
The abrasive chop saw for metal looks very similar to a wood chop saw, but it works differently. It uses a large, thin disc made of bonded abrasive material (like a giant grinding wheel).
When the disc spins fast, it grinds away the metal. This creates sparks and a lot of heat.
- Best For: Fast, straight cuts on solid stock, angle iron, and thick tubing.
- Downside: The cut is rough, and the metal heats up significantly. You must wear good safety gear because of the sparks.
Miter Saws and Metal Cutting
A standard miter saw for metal cutting is usually an abrasive chop saw mounted on a pivoting base. This lets you make precise angle cuts, just like a wood miter saw.
Some high-end specialized metal cutting saws use cold-cut circular blades (like the dry-cut saws mentioned above) but in a miter saw format. These are fantastic for construction where exact angles on structural steel are needed. They are expensive but produce clean, cool cuts.
Advanced and Professional Metal Cutting Saws
For fabrication shops or heavy industrial work, other types of saws offer higher precision and speed.
Band Saws for Cutting Metal
The band saw for cutting metal is a staple in metalworking shops. It uses a long, continuous loop of blade that runs over two or three wheels.
Horizontal vs. Vertical Band Saws
- Vertical Band Saws: These look like large scroll saws. They are used for cutting intricate shapes out of flat sheets of metal. They are excellent for fine, curved work.
- Horizontal Band Saws: These are the most common type for cutting stock material. The metal piece is clamped down, and the blade arm swings down (or the material feeds through the blade) to make a straight cut.
Why Band Saws Are Great for Metal:
- Continuous Cutting: Only a few teeth engage the metal at any time, which means less strain on the blade and less heat buildup.
- Precision: They offer very accurate, square cuts.
- Speed Control: Most models have variable speed control, allowing you to match the blade speed perfectly to the material (e.g., slow for stainless steel, fast for aluminum).
If you need speed and accuracy for repetitive straight cuts, the band saw for cutting metal is often the best saw for cutting metal.
Comparing Cutting Methods: Saw vs. Grinder vs. Plasma
Sometimes people confuse sawing with grinding or thermal cutting. It is important to know the differences between these metal cutting saws and other tools.
Hacksaw vs Angle Grinder for Metal
This is a common comparison for DIYers.
| Feature | Hacksaw | Angle Grinder (with Cut-Off Wheel) |
|---|---|---|
| Tool Type | Manual/Hand Tool | Power Tool |
| Cutting Action | Tooth abrasion (slicing) | High-speed grinding |
| Speed | Slow | Fast |
| Precision | Good, requires steady hand | Poor, prone to wandering |
| Heat/Sparks | Very little | Extreme heat and many sparks |
| Best For | Small tubing, bolts, soft metals | Quick removal, cutting very thick material where precision is not key |
An angle grinder cuts metal by wearing it away using friction. While fast, it is harder to keep straight than using any dedicated metal cutting saw.
Plasma Cutter vs Saw for Metal
A plasma cutter vs saw for metal is a comparison between two totally different technologies.
- Saws: Cut by physical action—teeth remove material. They leave a clean, measurable edge.
- Plasma Cutters: Use superheated, ionized gas (plasma) to melt through the metal. This is extremely fast, even on very thick steel.
A plasma cutter is ideal for cutting out complex shapes quickly or severing thick plate steel where the edge quality is not the top priority. A saw is better when you need a precise, square end on a piece of tube or bar stock.
Blade Technology: The Heart of Metal Cutting Saws
No matter which saw you choose, the blade dictates the success of the cut. For electric metal cutting saws, you will see two main blade types: bi-metal and carbide-tipped.
Bi-Metal Blades
These are common in reciprocating saws and portable band saws. They have a flexible steel body with high-speed steel (HSS) teeth welded onto the edge. They are durable and resist breaking under impact.
Carbide-Tipped Blades
These are used on dry-cut circular saws and specialized miter saws. They use extremely hard tungsten carbide tips brazed onto the blade body.
- Advantages: They stay sharp much longer, handle higher heat, and leave a finish that often requires no secondary finishing (like deburring).
- Disadvantages: They are more expensive and can shatter if used improperly (e.g., cutting wood or plunging into thick steel too fast).
Safety First When Cutting Metal
Cutting metal creates hazards beyond simple sawdust. Heat, sharp burrs, and flying sparks demand respect.
Essential Safety Gear for Metal Cutting:
- Eye Protection: Always wear safety glasses or goggles. Sparks and metal chips travel fast.
- Hand Protection: Wear heavy-duty work gloves, especially when handling freshly cut metal, which will be extremely hot.
- Hearing Protection: Power metal cutting saws and abrasive chop saws generate high noise levels. Protect your ears.
- Fire Safety: If using an abrasive chop saw or angle grinder, clear the area of flammable materials. Sparks can travel far.
When using any of the types of saws for metal, ensure the material is clamped down tightly. If the metal moves during the cut, you risk binding the blade or injuring yourself.
Applying the Right Saw to Specific Materials
The type of metal heavily influences the best cutting approach. Different alloys have different hardness levels and heat tolerance.
Cutting Aluminum
Aluminum is soft and gummy. It clogs up fine-toothed blades easily.
- Best Tool: A dedicated carbide-tipped circular saw or a low-TPI hacksaw.
- Technique: Use a high speed (for circular saws) and a specialized wax or lubricant to keep the aluminum from welding itself to the blade teeth.
Cutting Mild Steel (Iron)
This is the most common material. It is tough but manageable.
- Best Tool: A band saw for cutting metal is ideal for straight stock. An abrasive chop saw for metal is fastest for demolition or quick angle cuts.
- Technique: Use medium TPI blades and moderate speed. Lubrication helps maintain blade life.
Cutting Stainless Steel and Hard Alloys
These metals are very tough and generate high heat. Heat ruins the temper (hardness) of the blade teeth quickly.
- Best Tool: A specialized cold-cut saw or a slow-speed, high-torque band saw for cutting metal.
- Technique: Slow and steady wins. Keep the speed very low, use heavy pressure (if the tool allows), and constantly apply cutting fluid to dissipate heat.
Deep Dive: The Mechanics of Choosing a Circular Saw for Metal
Many DIYers try to adapt a wood saw, leading to frustration. Let’s focus purely on what makes a good circular saw for cutting metal.
RPM Matters Most
Wood saws spin around 5,000 RPM. This speed generates the heat needed to burn wood fibers. Metal needs to be sheared, not burned. If you spin a metal blade too fast, the carbide tips overheat and soften, dulling instantly.
- Dry-Cut Metal Saws: Operate between 1,200 to 2,000 RPM. This slow speed allows the sharp carbide teeth to cleanly sever the metal strands.
Blade Depth Adjustment
On a good metal-cutting circular saw, you must set the blade depth correctly. The blade should extend only about 1/8 to 1/4 inch below the material being cut. This ensures the maximum number of teeth are engaged safely and prevents excessive vibration.
Cool-Cut vs. Abrasive Wheels in Circular Form
It is important to distinguish between a true carbide-tipped saw blade and a metal-cutting abrasive wheel that looks like a circular blade.
- Carbide Blade: Reusable many times, cuts cool, precise.
- Abrasive Wheel: Consumable item, cuts hot, sparks everywhere, rougher finish.
If you see a large, thick disc that looks like sandpaper glued together mounted on a tool called a circular saw, you are using an abrasive system, similar to the abrasive chop saw for metal.
Final Comparison: Selecting the Best Saw
To help finalize your decision on the best saw for cutting metal, review where and how you plan to work.
| Application | Recommended Tool | Why It Works Best |
|---|---|---|
| Occasional small repairs (plumbing, bolts) | Hacksaw | Cheap, no power needed, good control. |
| Quick cuts on existing structures (demolition) | Reciprocating saw for metal | Portability and ability to cut pipes in place. |
| High volume, straight cuts in a workshop | Band saw for cutting metal (Horizontal) | Highest precision, best speed/quality balance. |
| Quick, clean angle cuts on tubing/studs | Dry-Cut Circular Saw | Fast, minimal burrs, clean finish. |
| Quick, rough angle cuts on structural shapes | Abrasive chop saw for metal | Very fast material removal for non-critical edges. |
| Intricate, curved shapes from sheet metal | Vertical Band Saw for cutting metal | Allows for tight turning radii. |
Frequently Asked Questions (FAQ)
Q: Can I use a regular wood saw blade to cut metal?
No, you cannot. Wood saw blades have large, sharp teeth designed to move wood fibers out of the way. On metal, these large teeth will catch, overheat instantly, break the blade, or throw sparks dangerously. Always use blades rated specifically for metal cutting saws.
Q: Is an angle grinder faster than a hacksaw vs angle grinder for metal?
Yes, an angle grinder is significantly faster than a hacksaw because it uses motor power to grind material away. However, the grinder produces much more heat, noise, and sparks, and the cut is less accurate than what you can achieve with a dedicated metal cutting saw.
Q: What is the main difference between a miter saw for metal cutting and a regular one?
A standard miter saw is designed for wood and spins too fast for metal, causing blades to fail. A metal miter saw either uses a very slow-spinning blade (a cold-cut saw) or uses a thick abrasive wheel instead of a toothed blade. They are built stronger to handle the forces involved in metal cutting.
Q: Is a plasma cutter vs saw for metal better for thick steel plate?
For very thick steel (over 1/2 inch), a plasma cutter is usually much faster than any saw, including an abrasive chop saw for metal. Saws struggle with extreme thickness due to heat and blade strain. Plasma melts the metal away quickly.
Q: What is the safest way to cut metal?
The safest power tool for general metal cutting is often a low-speed, carbide-tipped circular saw for cutting metal or a horizontal band saw for cutting metal, provided the material is firmly clamped. They generate less intense sparks and heat compared to abrasive methods.