Can I Cut Metal With a Miter Saw? Best Blades & Metals

Yes, you can cut metal with a miter saw, but only under specific conditions. You need the right blade and should only cut certain types of metal. Using a standard wood-cutting blade on metal is dangerous and will ruin the blade. This article will explain how to safely cut metal with a miter saw, which metals are suitable, and which blades to use.

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Selecting the Right Miter Saw Blade for Metal

The key to successfully using a miter saw for metal cutting is choosing the correct blade. A standard wood-cutting blade is not suitable and can be very dangerous. Metal-cutting blades are designed to withstand the heat and friction generated when cutting metal. Several types of metal-cutting blades are available.

Carbide-Tipped Blades: A Popular Choice

Carbide-tipped blades are a common choice for cutting metal with a miter saw. The carbide tips are much harder than steel, making them resistant to wear. These blades are good for cutting non-ferrous metals like aluminum, copper, and brass. They can also cut thin steel, but use caution.

Blade Features

• Tooth Count: A higher tooth count provides a smoother cut, especially important for metal. Aim for blades with 60-80 teeth for cutting aluminum and other non-ferrous metals.
• Tooth Geometry: Look for blades with a Triple Chip Grind (TCG) tooth geometry. This design helps to reduce heat and chipping.
• Kerf: A thinner kerf blade removes less material, which makes cutting more efficient and reduces the load on the saw.

Abrasive Blades: For Ferrous Metals

Abrasive blades, also called “cutoff wheels,” are made from bonded abrasive materials. They are designed to cut through ferrous metals like steel and iron. Abrasive blades wear down as they cut, so they have a limited lifespan.

Blade Features

• Reinforcement: Look for blades that are reinforced with fiberglass mesh for added strength and safety.
• Thickness: Thicker blades are more durable but remove more material.
• Speed Rating: Ensure the blade’s maximum speed rating matches or exceeds the miter saw’s speed.

Cold Cut Blades: A Premium Option for Metal

Cold cut blades are specifically designed for cutting metal without generating excessive heat. These blades use high-speed steel (HSS) teeth and a slower cutting speed. They produce clean, burr-free cuts. These are often referred to as cold cut miter saw metal blades.

Blade Features

• Material: HSS blades are very hard and durable.
• Tooth Design: Look for blades with specialized tooth designs for cutting specific types of metal.
• Lubrication: Using a coolant or lubricant is highly recommended when using cold cut blades.

Metals You Can Cut with a Miter Saw

Not all metals are suitable for cutting with a miter saw. The best candidates are softer, non-ferrous metals and thin ferrous metals.

Cutting Aluminum with a Miter Saw

Cutting aluminum with miter saw is quite common and relatively easy. Aluminum is a soft, non-ferrous metal that cuts cleanly with a carbide-tipped blade.

Tips for Cutting Aluminum

• Use a blade specifically designed for cutting aluminum with miter saw.
• Apply cutting wax or lubricant to the blade to prevent aluminum from sticking.
• Cut slowly and steadily.
• Wear safety glasses and hearing protection.

Cutting Copper and Brass

Like aluminum, copper and brass are soft, non-ferrous metals that are easy to cut with a carbide-tipped blade.

Tips for Cutting Copper and Brass

• Use a blade with a high tooth count.
• Apply cutting oil to the blade.
• Secure the material firmly to prevent vibration.

Can Miter Saw Cut Steel? Thin Steel Only

Can miter saw cut steel? Yes, but only thin steel profiles like tubing or sheet metal. Attempting to cut thick steel with a miter saw can be dangerous and damage the saw.

Tips for Cutting Thin Steel

• Use an abrasive blade or a cold cut blade.
• Cut slowly and apply light pressure.
• Wear a face shield to protect against sparks.
• Allow the blade to cool down periodically to prevent overheating.

Metals to Avoid Cutting

• Thick Steel: Miter saws lack the power and stability to safely cut thick steel.
• Hardened Steel: Hardened steel is too hard for most miter saw blades.
• Stainless Steel: Stainless steel is difficult to cut and can quickly dull blades.

Miter Saw for Metal: Converting Your Wood Miter Saw

While there are dedicated metal cutting miter saw models, you can adapt your existing wood miter saw for metal cutting. This involves making some adjustments and taking precautions.

Steps to Adapt a Wood Miter Saw for Metal

1. Replace the Blade: Install a metal-cutting blade suitable for the type of metal you intend to cut.
2. Reduce Speed: If your miter saw has variable speed, reduce the speed to the lowest setting. High speeds generate excessive heat when cutting metal.
3. Secure the Workpiece: Use clamps to firmly secure the metal to the saw’s fence. Metal tends to vibrate more than wood, so secure clamping is essential.
4. Lubricate the Blade: Apply cutting oil or wax to the blade before and during cutting. This helps to reduce friction and heat.
5. Cut Slowly: Cut slowly and steadily, allowing the blade to do the work. Forcing the blade can cause it to bind or break.
6. Clean the Saw: After cutting metal, thoroughly clean the saw to remove metal shavings. These shavings can cause rust and corrosion.

Safety Precautions When Cutting Metal with a Miter Saw

• Wear Safety Glasses or a Face Shield: Metal cutting produces sparks and debris that can injure your eyes.
• Wear Hearing Protection: Metal cutting can be very loud.
• Wear Gloves: Metal shavings can be sharp and can cut your hands.
• Work in a Well-Ventilated Area: Metal cutting can produce fumes.
• Keep Bystanders Away: Ensure that no one is standing close to the saw when cutting metal.
• Unplug the Saw: Always unplug the saw before changing blades or making adjustments.

Best Blade for Cutting Metal with Miter Saw: Reviews and Recommendations

Choosing the best blade for cutting metal with miter saw depends on the type of metal you plan to cut and your budget. Here are some recommendations:

Blade Type	Metal Compatibility	Key Features	Pros	Cons
Carbide-Tipped	Aluminum, Copper, Brass, Thin Steel	High tooth count, TCG tooth geometry, Thin kerf	Clean cuts, Long lifespan, Versatile	Not suitable for thick steel, Can be expensive
Abrasive	Steel, Iron	Reinforced with fiberglass, Various thicknesses, High speed rating	Inexpensive, Good for cutting ferrous metals	Wears down quickly, Can produce a lot of sparks and debris
Cold Cut (HSS)	Steel, Aluminum	High-speed steel teeth, Specialized tooth designs, Requires lubrication	Clean, burr-free cuts, Minimal heat generation	More expensive, Requires lubrication, Slower cutting speed

Specific Blade Recommendations

• For Aluminum: Freud D1080CF Aluminum Cutting Blade
• For Steel: DEWALT DW8876 Metal Cutting Abrasive Wheel
• For General Purpose: Oshlun SBNF-100080 10-Inch 80 Tooth Blade

Choosing Between Metal Cutting Miter Saw vs. Wood Miter Saw

Deciding whether to use a dedicated metal cutting miter saw or adapt a wood miter saw depends on the frequency and type of metal cutting you plan to do.

Metal Cutting Miter Saw

A dedicated metal cutting miter saw is designed specifically for cutting metal. These saws typically have:

• Lower RPMs to reduce heat.
• More robust construction to handle the stresses of metal cutting.
• Built-in coolant systems to lubricate the blade.

Advantages

• Optimized for metal cutting
• More durable for heavy use
• Safer than adapting a wood miter saw

Disadvantages

• More expensive than a wood miter saw
• Less versatile for cutting other materials

Wood Miter Saw Adapted for Metal

Adapting a wood miter saw for metal cutting can be a cost-effective option if you only occasionally need to cut metal.

Advantages

• More affordable
• Versatile for cutting wood and other materials

Disadvantages

• Not optimized for metal cutting
• Can be less durable
• Requires careful setup and operation

Miter Saw Metal Cutting Blade Maintenance

Proper maintenance of your miter saw metal cutting blade will extend its lifespan and ensure optimal performance.

Cleaning

• Clean the blade after each use to remove metal shavings and debris. Use a wire brush or compressed air.

Sharpening

• Carbide-tipped blades can be sharpened by a professional sharpening service.
• Abrasive blades cannot be sharpened and must be replaced when they wear down.
• HSS blades can be sharpened with specialized sharpening equipment.

Storage

• Store blades in a dry place to prevent rust and corrosion.
• Use a blade guard to protect the teeth from damage.

Fathoming the Costs: Metal Cutting Miter Saw vs. Wood Miter Saw

Feature	Metal Cutting Miter Saw	Wood Miter Saw with Metal Blade
Initial Cost	Higher	Lower
Blade Cost	Moderate	Moderate
Maintenance Cost	Moderate	Lower
Long-Term Durability	Higher	Lower
Safety	Higher	Lower
Metal Cutting Volume	High	Low to Moderate
Wood Cutting Ability	Low	High

FAQ Section

Q: Is it safe to cut metal with a wood miter saw?

A: Yes, but only if you use the right blade and follow safety precautions. Use a metal-cutting blade, reduce the saw’s speed, and secure the workpiece firmly.

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

A: It’s not recommended. Stainless steel is difficult to cut and can quickly dull blades.

Q: What is the best blade for cutting aluminum with a miter saw?

A: A carbide-tipped blade with a high tooth count (60-80 teeth) is ideal for cutting aluminum.

Q: How do I prevent the metal from sticking to the blade?

A: Apply cutting wax or lubricant to the blade before and during cutting.

Q: What safety gear should I wear when cutting metal with a miter saw?

A: Always wear safety glasses or a face shield, hearing protection, and gloves.

By following these guidelines, you can safely and effectively cut metal with a miter saw. Remember to choose the right blade, use proper techniques, and always prioritize safety. Whether you opt for a dedicated non-ferrous metal miter saw or adapt your existing wood miter saw, you can achieve professional-quality results.