Can Reciprocating Saw Cut Metal? Blades & Techniques Explained

Yes, a reciprocating saw can cut metal, but success depends on using the right blade and technique. This article dives deep into how to choose the correct metal cutting blades for reciprocating saw, the best reciprocating saw for metal, and crucial recip saw metal cutting guide strategies. Whether you want to reciprocating saw cut steel or reciprocating saw cut aluminum, this guide provides the information you need.

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Choosing the Right Blade for Metal Cutting

The most crucial factor in using a metal cutting reciprocating saw is the blade. A general-purpose wood-cutting blade will be quickly ruined, produce poor results, and even be dangerous. Using the right blade designed for metal significantly impacts the speed, quality, and safety of your cut.

TPI: Teeth Per Inch

The number of teeth per inch (TPI) is a key factor. For metal, blades with a higher TPI are necessary.

• High TPI (18-24 TPI): Ideal for thin metals like sheet metal, small pipes, and tubing. They provide a smoother, more controlled cut.
• Medium TPI (10-18 TPI): A good choice for thicker metals like steel studs, rebar, and angle iron. Offers a balance of cutting speed and finish.
• Low TPI (6-10 TPI): Used for very thick metals and demolition work where speed is more important than a clean cut.

Blade Material

Different blade materials are better suited for specific metals and applications.

• Bi-Metal Blades: The most common and versatile choice for metal cutting. They combine a flexible steel body with high-speed steel teeth, offering durability and resistance to breakage. They are great for reciprocating saw cut steel and aluminum.
• High-Speed Steel (HSS) Blades: Harder than bi-metal blades and are better for cutting harder metals such as hardened steel, but they are more brittle.
• Carbide-Tipped Blades: The most durable and long-lasting option. Carbide teeth can withstand high heat and abrasion, making them ideal for cutting extremely hard metals like cast iron and stainless steel. They offer excellent performance but are usually more expensive.

Understanding Blade Length and Thickness

Blade length is important for reaching difficult areas, while blade thickness impacts stability.

• Length: Choose a blade long enough to extend through the material you’re cutting plus a little extra. A blade that’s too short can be hard to control.
• Thickness: Thicker blades are more rigid and less prone to bending or breaking, especially when cutting thicker metal.

Metal Cutting Sawzall Blades Comparison Table

Blade Type	TPI	Material(s)	Best Use Case	Pros	Cons
Bi-Metal	10-24 TPI	Steel, Aluminum	General metal cutting, pipes, studs	Durable, versatile, resists breakage	May wear out faster than carbide on very hard metals
High-Speed Steel	18-32 TPI	Hardened Steel	Precision cuts in hard metals	High hardness, good for fine cuts	Brittle, can break easily if misused
Carbide-Tipped	6-14 TPI	Cast Iron, Steel	Heavy-duty cutting, abrasive materials	Extremely durable, long-lasting, resists heat and abrasion	More expensive than bi-metal or HSS blades

Choosing the Right Reciprocating Saw

While the blade is critical, the saw itself also plays a significant role in metal cutting reciprocating saw performance.

Corded vs. Cordless

Both corded and cordless reciprocating saws have advantages.

• Corded: Offer consistent power and are ideal for long, continuous cutting tasks. No need to worry about battery life.
• Cordless: Provide greater portability and convenience, especially for jobs in remote locations or when working at heights. Advances in battery technology have made cordless models very powerful.

Motor Power

A more powerful motor will cut through metal more easily and quickly. Look for models with at least 8 amps (corded) or 18 volts (cordless) for metal-cutting applications.

Variable Speed Control

Variable speed control is essential for metal cutting. Lower speeds are generally better for metal to prevent overheating and prolong blade life.

Orbital Action

Orbital action, where the blade moves in a slight circular motion, can increase cutting speed in wood but is not recommended for metal. It can cause the blade to bounce and create a rough cut. Turn off orbital action when cutting metal.

Vibration Reduction

Metal cutting can create a lot of vibration. Look for saws with vibration-reducing features to improve comfort and control.

Adjustable Shoe

An adjustable shoe allows you to control the depth of cut and use different parts of the blade, extending its life.

Best Reciprocating Saw for Metal Considerations

Here’s what to consider when selecting the best reciprocating saw for metal:

• Power: Adequate power for cutting through the types of metal you’ll be working with.
• Blade Change System: A tool-free blade change system makes swapping blades quick and easy.
• Durability: A robust build quality that can withstand the demands of metal cutting.
• Ergonomics: Comfortable to hold and use, with features like a soft grip and good balance.
• Features: Variable speed, adjustable shoe, and vibration reduction.

How to Cut Metal With a Reciprocating Saw

With the right blade and saw in hand, the next step is learning the proper techniques.

Safety First

Always wear safety glasses, gloves, and hearing protection when cutting metal. Metal shards and sparks can cause serious injury.

Secure the Workpiece

Clamp the metal securely in a vise or with clamps to prevent it from moving during cutting. This is crucial for both safety and accuracy.

Mark the Cut Line

Use a marker or scribe to clearly mark the cutting line on the metal.

Starting the Cut

Start the cut at a slow speed and at a slight angle to the cutting surface. This helps to prevent the blade from skipping or bouncing. Once you have a groove established, gradually increase the speed and bring the saw to the marked line.

Applying Pressure

Let the blade do the work. Applying too much pressure can cause the blade to overheat and break. Use a steady, even pressure and allow the saw to cut at its own pace.

Using Cutting Oil

Applying cutting oil or lubricant to the blade and workpiece can significantly improve cutting performance and extend blade life. It reduces friction and heat, resulting in a cleaner, smoother cut.

Controlling Vibration

Metal cutting can generate a lot of vibration. Use a firm grip on the saw and try to brace yourself against a solid surface.

Coping with Heat

Metal cutting generates heat. Pause frequently to allow the blade to cool down, especially when cutting thicker metals.

Cutting Different Types of Metal

Different metals require different techniques.

Reciprocating Saw Cut Steel

For reciprocating saw cut steel, use a bi-metal or carbide-tipped blade with a medium to high TPI. Apply moderate pressure and use cutting oil to keep the blade cool.

Reciprocating Saw Cut Aluminum

When you reciprocating saw cut aluminum, use a bi-metal blade with a higher TPI. Aluminum is softer than steel and can clog the blade. Use cutting oil and a slower speed to prevent this.

Reciprocating Saw Metal Cutting Techniques for Specific Shapes

• Pipes and Tubing: Use a pipe clamp or vise to secure the pipe. Start the cut slowly and rotate the pipe as you cut to ensure a straight line.
• Sheet Metal: Clamp the sheet metal between two pieces of wood to prevent it from vibrating. Use a high TPI blade and apply light pressure.
• Angle Iron: Secure the angle iron in a vise and use a medium TPI blade. Start the cut at the corner and gradually work your way down.

Recip Saw Metal Cutting Guide: Step-by-Step

1. Gear Up: Safety glasses, gloves, hearing protection.
2. Secure Metal: Vise or clamps.
3. Mark Cut: Use a marker.
4. Select Blade: Correct TPI and material.
5. Lubricate: Apply cutting oil.
6. Start Slow: Angle the blade.
7. Steady Pressure: Let the blade do the work.
8. Cool Down: Pause to avoid overheating.
9. Clean Up: Remove burrs and sharp edges.

Fathoming Metal Cutting With a Reciprocating Saw: Advanced Tips

• Plunge Cutting: To make a plunge cut (cutting into the middle of a piece of metal), tilt the saw forward with the shoe resting on the metal. Slowly lower the blade into the metal until it penetrates.
• Curved Cuts: While not ideal for tight curves, a reciprocating saw can make gentle curves in metal. Use a narrow blade with a high TPI and move the saw slowly and deliberately.
• Demolition Work: For demolition work, a reciprocating saw is invaluable. Use a demolition blade designed for cutting through nails, screws, and other embedded objects.

Common Problems and Solutions

• Blade Breakage: Using the wrong blade, applying too much pressure, or cutting at too high a speed.
• Blade Clogging: Aluminum and other soft metals can clog the blade. Use cutting oil and a slower speed.
• Rough Cuts: Using a dull blade or too low a TPI.
• Vibration: Secure the workpiece properly and use a saw with vibration reduction.

FAQ: Cutting Metal with a Reciprocating Saw

Q: Can I use any reciprocating saw blade to cut metal?

No. Using the wrong blade can damage the blade, the saw, and potentially cause injury. Use blades specifically designed for metal cutting.

Q: What TPI blade should I use for cutting metal?

The ideal TPI depends on the thickness and type of metal. High TPI (18-24) for thin metals, medium TPI (10-18) for thicker metals, and low TPI (6-10) for very thick metals.

Q: Do I need to use cutting oil when cutting metal with a reciprocating saw?

Yes, cutting oil is highly recommended. It reduces friction and heat, resulting in a cleaner cut, extending blade life, and preventing blade clogging.

Q: Can a reciprocating saw cut stainless steel?

Yes, but you’ll need a carbide-tipped blade and a slow, steady cutting speed. Stainless steel is a hard metal that can quickly wear out blades.

Q: Is a corded or cordless reciprocating saw better for cutting metal?

Both can work well. Corded saws offer consistent power, while cordless saws provide greater portability. Choose based on your specific needs and job site conditions.

Q: How do I prevent the blade from skipping when starting a cut?

Start the cut at a slight angle and at a slow speed. Once you have a groove established, gradually increase the speed and bring the saw to the marked line.

Q: How do I maintain my reciprocating saw blades?

Clean the blades after each use and store them in a dry place. Replace dull or damaged blades promptly.

Q: Can I cut hardened steel with a reciprocating saw?

Yes, but it requires a high-speed steel (HSS) or carbide-tipped blade and a very slow, steady cutting speed. Hardened steel is extremely hard and can quickly wear out blades.

Q: What is the best way to cut thick metal with a reciprocating saw?

Use a low TPI, carbide-tipped blade, apply cutting oil, and cut at a slow, steady speed. It may take multiple passes to cut through very thick metal.

Conclusion: Mastering Metal Cutting with a Reciprocating Saw

A reciprocating saw can be a versatile tool for cutting metal, but success hinges on selecting the right blade, using proper techniques, and prioritizing safety. By following this recip saw metal cutting guide, understanding blade types, and choosing the best reciprocating saw for metal based on your needs, you can confidently tackle various metal-cutting projects with precision and efficiency. Always remember to secure your workpiece, use cutting oil, and let the blade do the work to achieve the best results and ensure a safe working environment.