Can a Reciprocating Saw Cut Metal? Best Metal Cutting Blades

Yes, a reciprocating saw can cut metal! However, success depends on using the right blade and techniques. This article will guide you through everything you need to know about using a metal cutting reciprocating saw, from selecting the best blade to mastering safe cutting practices.

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Choosing the Right Metal Cutting Reciprocating Saw Blade

The key to successfully cutting metal with a metal cutting reciprocating saw is using the correct blade. A wood-cutting blade will quickly dull and may even break. Here’s what to look for:

Blade Material

• Bi-Metal Blades: These are the most common and versatile metal cutting sawzall blades. They consist of high-speed steel (HSS) teeth welded to a flexible alloy steel body. This combination provides both durability and flexibility, making them suitable for various metals.
• Carbide-Tipped Blades: Carbide teeth are extremely hard and heat-resistant. These metal cutting reciprocating saw blades are ideal for cutting through very hard metals like cast iron, stainless steel, and hardened alloys. They last much longer than bi-metal blades but are also more expensive.

Teeth Per Inch (TPI)

TPI refers to the number of teeth per inch of the blade. The TPI dictates the type of cut you’ll get.

• High TPI (18-24 TPI): Use these blades for thin metals like sheet metal, tubing, and small pipes. The finer teeth prevent the blade from snagging or stripping the metal.
• Medium TPI (10-18 TPI): These blades are suitable for general-purpose metal cutting, including thicker pipes, metal studs, and rebar.
• Low TPI (6-10 TPI): These blades are designed for cutting thick metal, such as cast iron pipes or large metal beams. They remove material quickly but leave a rougher cut.

Blade Length and Width

• Length: Choose a blade long enough to extend completely through the material you are cutting. A longer blade can also be useful for plunge cuts. Common lengths range from 6 to 12 inches.
• Width: Wider blades are more stable and resist bending, resulting in straighter cuts. Narrower blades are better for curved cuts or tight spaces.

Blade Features

• Tooth Design: Some metal cutting reciprocating saw blades feature specialized tooth designs, such as variable pitch teeth (where the TPI changes along the blade’s length) for improved cutting speed and reduced vibration.
• Reinforced Shank: Look for blades with a reinforced shank (the part that connects to the saw) for increased durability and reduced breakage.

Comparison Table: Best Reciprocating Saw for Metal Blades

Blade Type	Material Suitability	TPI Range	Pros	Cons	Best For
Bi-Metal	Steel, aluminum, copper, cast iron	10-24	Versatile, durable, good value	Not ideal for very hard metals	General metal cutting, pipes, studs
Carbide-Tipped	Stainless steel, hardened alloys, cast iron	6-18	Extremely durable, long-lasting, cuts through very hard metals	More expensive, can be brittle	Hard metals, abrasive materials
High TPI	Thin sheet metal, tubing	18-24	Clean cuts, prevents snagging	Slower cutting speed, not for thick materials	Thin metal, intricate cuts
Low TPI	Thick metal, cast iron	6-10	Fast cutting speed, aggressive material removal	Rough cuts, more vibration	Demolition, thick metal components

Reciprocating Saw for Metal: Choosing the Right Tool

While any reciprocating saw can cut metal with the right blade, some saws are better suited for metal cutting than others. Here’s what to consider:

• Power: Look for a saw with a powerful motor (at least 8 amps) for cutting through tough metals. Corded saws generally offer more power than cordless models.
• Variable Speed: A variable speed trigger allows you to control the cutting speed, which is crucial for different metals. Slower speeds are ideal for hard metals, while faster speeds are better for softer metals.
• Orbital Action: Orbital action moves the blade in an oval pattern, which can increase cutting speed in some materials. However, it’s not always ideal for metal cutting, as it can cause the blade to bounce and reduce precision. A saw with adjustable or disable-able orbital action is best.
• Vibration Control: Metal cutting can generate significant vibration. Look for a saw with vibration reduction technology to reduce fatigue and improve control.
• Blade Change System: A tool-free blade change system makes swapping blades quick and easy.

Metal Demolition with Reciprocating Saw: Techniques

Metal demolition with a metal cutting reciprocating saw, or sawzall, requires proper technique.

• Secure the Workpiece: Always clamp the metal securely to prevent it from moving or vibrating during cutting.
• Start Slowly: Begin the cut at a slow speed to avoid damaging the blade or the material.
• Apply Steady Pressure: Let the blade do the work. Avoid forcing the saw, as this can cause the blade to bind or break.
• Use Cutting Oil: Applying cutting oil or lubricant can help reduce friction and heat, extending the life of the blade and improving the cut quality.
• Maintain a Straight Line: Guide the saw along the cutting line, keeping the blade perpendicular to the material.
• Plunge Cuts: For plunge cuts (cutting into the middle of a material), tilt the saw forward slightly and slowly lower the blade into the metal.

Can Sawzall Cut Through Metal Pipes?

Yes, a sawzall can cut through metal pipes. This is a common application for metal cutting reciprocating saws, especially in plumbing and demolition work.

• Choosing the Right Blade: Use a bi-metal blade with a medium TPI (10-18 TPI) for most metal pipes. For thicker cast iron pipes, use a carbide-tipped blade with a low TPI (6-10 TPI).
• Cutting Technique: Secure the pipe firmly. Start the cut slowly and apply steady pressure. Rotate the pipe as you cut to ensure a clean, even cut all the way around.
• Safety: Always wear safety glasses and gloves when cutting metal pipes. Be aware of any potential hazards, such as gas lines or electrical wires.

Cutting Steel with Reciprocating Saw

Cutting steel with a metal cutting reciprocating saw requires a methodical approach.

• Material Thickness: For thin steel sheets, a high TPI blade (18-24 TPI) will minimize tearing. For thicker steel, a medium TPI (10-18 TPI) blade is preferable.
• Blade Selection: Bi-metal blades work well for mild steel. For tougher steel alloys, consider a carbide-tipped blade.
• Cutting Speed: Use a slower speed to prevent the blade from overheating and dulling quickly.
• Lubrication: Apply cutting oil liberally to keep the blade cool and lubricated.
• Pressure: Avoid excessive force. Let the blade cut at its own pace.
• Spark Management: Cutting steel will produce sparks. Make sure the surrounding area is clear of flammable materials.

Reciprocating Saw Metal Cutting Techniques: Tips and Tricks

Here are some additional tips to improve your metal cutting with a metal cutting reciprocating saw:

• Start with a Pilot Hole: For plunge cuts, drill a pilot hole to guide the blade and prevent it from wandering.
• Use a Guide: Clamp a straight edge or a piece of wood to the metal to act as a guide for straighter cuts.
• Control Vibration: Grip the saw firmly with both hands and brace yourself against a solid surface to minimize vibration.
• Cool the Blade: If the blade starts to overheat, stop cutting and allow it to cool down. You can also dip the blade in cutting oil.
• Sharpen the Blade (Carefully): While not recommended for most users, experienced users can carefully sharpen bi-metal blades with a file. Carbide-tipped blades should be professionally sharpened.
• Change Blades Regularly: Don’t wait until the blade is completely dull to replace it. A sharp blade will cut faster, cleaner, and safer.

Reciprocating Saw Metal Cutting Safety: Prioritize Protection

Safety is paramount when cutting metal with a metal cutting reciprocating saw. Here are some essential safety precautions:

• Wear Safety Glasses: Always wear safety glasses or a face shield to protect your eyes from flying metal chips.
• Wear Gloves: Wear work gloves to protect your hands from sharp edges and hot metal.
• Wear Hearing Protection: Metal cutting can be noisy. Wear earplugs or earmuffs to protect your hearing.
• Wear Appropriate Clothing: Avoid loose clothing that could get caught in the saw. Wear long sleeves and pants to protect your skin from sparks and hot metal.
• Secure the Workpiece: Always clamp the metal securely to prevent it from moving during cutting.
• Work in a Well-Ventilated Area: Metal cutting can produce fumes. Work in a well-ventilated area or wear a respirator.
• Inspect the Saw and Blade: Before each use, inspect the saw and blade for damage. Replace any worn or damaged parts.
• Be Aware of Your Surroundings: Keep bystanders at a safe distance and be aware of any potential hazards, such as electrical wires or gas lines.
• Unplug the Saw: When changing blades or making adjustments, unplug the saw to prevent accidental starts.
• Use Common Sense: Always use common sense and follow the manufacturer’s instructions when operating a metal cutting reciprocating saw.

Fathoming Blade Costs and Lifespan

The cost of metal cutting reciprocating saw blades varies depending on the material, TPI, length, and brand. Bi-metal blades are generally more affordable than carbide-tipped blades. High-quality blades can range from $10 to $50 each.

The lifespan of a blade depends on the type of metal you are cutting, the cutting technique, and the quality of the blade. Carbide-tipped blades will last much longer than bi-metal blades, especially when cutting hard metals. To extend the life of your blades, use cutting oil, avoid forcing the saw, and change blades regularly.

Troubleshooting Common Problems

• Blade Binding: If the blade binds in the metal, stop cutting and try reducing the cutting speed or applying more cutting oil. Make sure the blade is sharp and appropriate for the material.
• Excessive Vibration: Excessive vibration can be caused by a dull blade, loose workpiece, or incorrect cutting speed. Check these factors and make adjustments as needed.
• Blade Breakage: Blade breakage can be caused by forcing the saw, using the wrong blade for the material, or hitting an obstruction. Use the correct blade and cutting technique to prevent breakage.
• Rough Cuts: Rough cuts can be caused by a dull blade, too few TPI, or excessive cutting speed. Use a sharp blade with the appropriate TPI and reduce the cutting speed.

Frequently Asked Questions (FAQ)

Q: What is the best reciprocating saw for cutting metal?

A: There isn’t one “best” saw, as the ideal choice depends on your specific needs and budget. Look for a saw with a powerful motor (8+ amps), variable speed, vibration control, and a tool-free blade change system. Brands like Milwaukee, DeWalt, and Bosch are known for their quality reciprocating saws.

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

A: Yes, but you’ll need a high-quality, carbide-tipped blade designed for stainless steel. Use a slow cutting speed and plenty of cutting oil to prevent the blade from overheating.

Q: Can a sawzall cut through metal pipes?

A: Yes, a sawzall is commonly used for cutting metal pipes. Use a bi-metal blade with a medium TPI (10-18 TPI) for most pipes, or a carbide-tipped blade with a low TPI (6-10 TPI) for cast iron pipes.

Q: How do I prevent the blade from binding when cutting metal?

A: Use the right blade for the material, apply cutting oil, avoid forcing the saw, and use a slower cutting speed.

Q: Is it safe to cut metal with a reciprocating saw indoors?

A: It’s generally not recommended due to the risk of sparks, fumes, and metal chips. If you must cut metal indoors, ensure adequate ventilation and take precautions to protect yourself and your surroundings.