Best Table Saw Blade for Cutting Aluminum: Cut Aluminum Like Never Before

The circular saw we know as the table saw was first made almost 250 years ago. But the original table-mounted circular saw showed up 100 years later. The first portable table saw came up another 50 years later. Those table saws were run by treadle pedals, as we see on old sewing machines.

Modern table saws are very efficient with the ability to cut many different materials, provided that they are equipped with the right blade. In this write-up, we will find out the best table saw blade for cutting aluminum and discuss different aspects that make a table saw blade worthy of you money.

Let’s begin.

Teeth Per Inch of Diameter Needed for Aluminum of Different Thicknesses

The general rule is, higher TPI provides a better finish. But lower TPI is required for thicker materials. In the case of low TPI blades, deeper gullets make the chiseling through thick materials more aggressive.

Special blades are required for cutting non-ferrous metals like aluminum. TPI is calculated depending on the diameter of the blade. For example, if the diameter of the blade is 10 inches and it has 100 teeth, we know it has a TPI of 10.

For cutting aluminum up to 1/8 inches thick, a blade with 10 teeth per inch will be appropriate. As the thickness goes up, the number of teeth per inch will be reduced. Look at this table to get a clear idea.

Thickness of Aluminum	Teeth Per Inch of Diameter
1/8 inches or below	10
1/8 – 1/4 inches	8
Thicker than 1/4 inches	6

Best Table Saw Blade Reviews for Cutting Aluminum

We compiled these products after filtering them through different factors. Know the ins and outs of them to find out the best aluminum cutting blade for a table saw.

1. Oshlun SBNF-100060 TCG Saw Blade

Key Features

• Material: C-1 Micro Grain Tungsten Carbide
• Diameter: 10 inches
• Number of teeth: 60
• TPI: 6
• Arbor: 5/8 inches
• Max RPM: 5,800
• Used For: Non-ferrous metals

This blade has a lower TPI that indicates its suitability for cutting thicker sheets of aluminum. It can also cut other non-ferrous metals. You can even cut plastics with this blade.

The blade houses triple chip grind teeth with special tungsten carbide tips. TCG is advantageous in the case of non-ferrous metals as it provides a low tooth drag and a balanced cutting force. It also eliminates chipping by dividing them in the case of hard and brittle materials.

 

These tips are more durable than normal carbide teeth. Because of the copper plugged extension slots, this blade will work more silently than many other blades.

But the negative hook angle can be a safety issue if you’re not cautious enough. You will need proper clamping accessories to keep the aluminum sheet attached to the table. Lubrication during operation is also recommended to protect the teeth from wear and tear.

This is a moderately-priced blade that is best for thick aluminum and other non-ferrous metals. Super sharp and effective.

2. Evolution Power Tools 12BLADEAL Aluminum Cutting Saw Blade

Key Features

• Material: High-Grade Carbide
• Diameter: 12 inches
• Number of Teeth: 80
• Bore: 1 inch
• Kerf: 0.086 inches
• Max RPM: 1,600

The number of TPI is approximately in the middle of the range. So, it will be best for medium aluminum sheets. This table saw blade for aluminum is made of a hardened blade body and high-grade carbide teeth.

The number of teeth per inch of diameter is suitable for cutting aluminum sheets of 1/8 to 1/4 inches of thickness. As the kerf on this blade is on the thinner side, it will produce cleaner edges than full kerf blades.

The amount of shaving increases with full kerf blades. You don’t need to tolerate that in this case.

The blade runs at a very low RPM. It will give the optimum performance only when paired with a saw from the same manufacturer.

As less heat and burr are produced while cutting with this blade, the finished material can be handled faster. This blade is also faster and flexes less than many other blades for cutting aluminum.

This non-abrasive aluminum chop saw blade can be one of your top choices.

3. Diablo D1080N Cutting Saw Blade

Key Features

• Material: Micro Grain Titanium Carbide
• Diameter: 10 inches
• Number of Teeth: 80
• Teeth Per Inch: 8
• Kerf: .094 inches
• Hook Angle: -5 degrees
• Max RPM: 6,000

Diablo blade has a triple chip grind tooth designed for smooth, burr-free cuts. There are 8 teeth per inch of diameter, which is suitable for cutting non-ferrous metals or plastics of 1/8 inches to 1/4 inches thickness.

Laser-cut stabilizer vents in this blade trap noise and vibration. As a result, the blade becomes more durable. Shock-resistant brazing takes durability even further.

 

Heat expansion slots of the blade are also laser-cut. They will help the blade expand when extremely heated so that the blade provides straight and clean cuts and doesn’t warp.

On either side of the blade, there is a special coating resisting heat and corrosion. As a result, you will be able to use this blade with different types of saws for a longer period.

Its versatility, sturdy teeth and body, better control and precision, and overall performance make it the best value for money aluminum cutting blade for a miter saw or table saw, etc.

4. DEWALT DW7296PT Miter Saw Blade

Key Features

• Material: Micro Grain Carbide
• Diameter: 12 inches
• Number of Teeth: 96
• Teeth Per Inch: 8
• Kerf: .106
• Hook Angle: -5 degrees
• Max RPM: 4,800

This aluminum cutting blade for miter saw is extremely useful for making crosscuts. As you all might know, miter saws can cut more precisely from circular saws.

DEWALT blade will take the performance to the next level with 8 sharp TCG teeth per inch. As a result, it will cut aluminum, plastic, or other non-ferrous metals like a hot knife cutting through butter.

 

TCG geometry of the teeth provides a better bite for every cutting. With this many teeth per inch, it will be suitable for crown molding, making door frames or window casing with aluminum sheets of thicknesses from 1/8 inches to 1/4 inches.

The blade has a very good overall balance due to the laser-cut body. It precisely makes every cut and vibrates less due to 4 dampening slots on the blade body.

Excellent heat and corrosion resistance make this the best for heavy-duty work. Tune the blade with your miter saw and see it crosscutting plenty of non-ferrous metals.

5. TWIN-TOWN 10 Aluminum Cutting Saw Blade

Key Features

• Material: Alloy Steel & C4 Tungsten Carbide
• Diameter: 10 inches
• Number of Teeth: 80
• Teeth Per Inch: 8
• Kerf: .09 inches
• Arbor: 5/8 inches
• Max RPM: 5,500 RPM

The first mentionable thing here is the use of construction-grade carbide and alloy steel to make this blade. Those carbide blades have a TCG tooth geometry that will give a smoother and finer cut.

Another noticeable thing is the weight of the blade. As it is more suitable for use with miter saws, excessive weight can cause fatigue faster. This blade weighs just 1.6 lbs.

 

It is commonly used for cutting aluminum with a table saw or a miter saw. But this metal cutting blade is also suitable for other non -ferrous metals and even plastics.

Expansion slots are laser cut in this blade, which is a very common feature. But this will allow you to run the blade for a longer period without worrying about the heat or straightness of the cuts.

You get a tracking number of the product to cross-check whether the product you have got is original or not. This is a very good initiative from the manufacturer.

Considering all these factors, this is the best for budget; we kid you not. It will give you that similar performance to a highly-priced blade.

6. Oshlun SBNF-120120 Saw Blade

Key Features

• Material: C-1 Micro Grain Tungsten Carbide
• Diameter: 12 inches
• Number of Teeth: 120
• Teeth Per Inch: 10
• Arbor: 1 inch
• Max RPM: 5,000

With 10 teeth per inch of diameter, it is the best for thin aluminum sheets. Its TCG teeth are designed to have a negative hook angle. Though it is quite a safety risk, you can reduce the chance of hazards by clamping the sheets properly.

You might have already seen another product of the same brand at the top of the list with a different diameter. But the similarity of these blades is their target material. This blade is also effective for aluminum, bronze, brass, copper, and other non-ferrous metals.

As the diameter is greater than the previously mentioned blade, its max RPM is a bit lower. It is also heavier than many other blades in this category, with a weight of about 3 lbs.

Expansion slots on the blade are copper plugged in the same manner. So, you can expect a less noisy environment while cutting sheet aluminum.

The vibration will also be reduced along with the heat. As a result, the working life of the blade gets extended.

Its extreme precision, corrosion resistance, durable teeth, and body, make it one of the most popular choices for cutting aluminum.

7.  MASTEC 100T Aluminum Saw Blade

Key Features

• Material: Carbide
• Diameter: 10 inches
• Number of Teeth: 100
• Teeth Per Inch: 10
• Arbor: 5/8 inches
• Max RPM: 5,000

Another circular saw blade for aluminum, for thin aluminum to be more specific. With 10 teeth per inch of diameter, it is suitable for aluminum sheets thinner than 1/8 inches.

It has the same tooth geometry as most of the products listed here. This is a common characteristic of aluminum cutting blades because of their cleaner cuts with less chipping.

The body of the blade is made of hardened steel. Due to the laser-cut expansion slots on the body, it can dissipate heat much quicker.

For the same reason, it has the required space to expand and keep the cut straight even when the blade is performing for a long period.

Take a look at the price too. It is one of the best affordable blades you will find out there. The weight of the blade is on the lighter side but not too light to lose its balance.

Versatility is another great characteristic of this blade. You can pair it with different saws to cut a bunch of non-ferrous metals and non-metals like plastic or plexiglass.

The same manufacturer offers other variations of the blade too, so you have all the necessary options.

8. TOMAX TMA10801 Circular Saw Blade

Key Features

• Material: Carbide
• Diameter: 10 inches
• Number of Teeth: 80
• Teeth Per Inch: 8
• Arbor: 5/8 inches
• Max RPM: 5,500

TOMAX can be the best circular blade for the budget. Whether you want to cut aluminum, other non-ferrous metals, or plastics, this blade will serve the purpose.

It has a great shiny body that comes from the electrophoretic coating. This helps the blade keep its shine for longer, even after frequent use. It also provides rust and corrosion resistance.

 

The TPI number is perfect for cutting aluminum sheets of medium thickness, up to 1/4 inches, to be specific. It will neither feel heavy under your hands nor in your pocket. This handy tool weighs less than 1.6 lbs.

You can rely on this blade for crosscutting. The expansion slots on the body are spaced enough to keep the blade straight in any conditions. Those TCG teeth are guaranteed to give you the cleanest cuts possible.

Table Saw Blade for Cutting Aluminum Buying Guide

Choosing a metal cutting table saw blade is a tricky job. You need to focus on several factors at the same time to make sure you are investing in the right tool. If not selected wisely, a table saw blade can cause serious hazards in addition to ruining your projects.

Let’s take a closer look at the factors you need to check before buying a table saw blade for cutting aluminum.

Teeth Type

The first thing you should observe is the geometry of the tooth of saw blades. They are of four types. But the TCG tooth is the right choice for cutting aluminum.

In TCG or Triple Chip Grind blades, you will see two different tooth grinds in the same blade. One of them is called a flat top grind, and the other is called a trapezoidal top grind.

The second type is almost the same as the first type, but it is chamfered at both sides. As a result, the top of the trapezoidal tooth is slightly higher and sharper than the flat top tooth.

They are positioned alternatively, meaning one raker tooth after one chamfered tooth. The first one makes a rough cut, and the raker finalizes the cut to give a smooth finish.

This type of tooth is essential for cutting non-ferrous metals like aluminum, brass, and non-metals like plastic, Corian, etc.

Blade Material

Table saw blades or circular saw blades are commonly made with two materials. The blade body is usually made with hardened steel.

Teeth are often made from carbide. Though the quality of the carbide used in the teeth varies depending on the manufacturer, you should go for at least a blade that has C4 graded carbide teeth.

High-quality carbide teeth will give cleaner cuts and require resharpening less frequently.

Teeth Per Inch

Teeth per inch or TPI expresses the frequency of teeth on the blade. Blades with low TPI will cut a lot quicker. But the result of the cut isn’t as clean as high TPI blades. These blades are better for rip cuts but will cause rough surfaces during crosscuts.

Low TPI blades are commonly used for cutting thick aluminum. As the teeth have larger gullets, in this case, each cut removes a larger portion.

With high TPI blades, you can expect a cleaner and smoother cut. These blades are useful for crosscutting. They are popularly used for cutting thin materials. The only inconvenience of cutting with these blades is you have to keep the feed rate low.

Kerf

Technically, the kerf is the term to denote the width a saw blade can cut. But the width of a cut isn’t always the same, even if you use the same blade. Why does this happen? This happens because the width of each blade isn’t always the same.

Also, the same amount of material is never pulled out. The width or the thickness of the cut can also vary due to the wobble of the blade caused by excess vibration.

If the kerf of a blade is more than .126 inches, it is called a full kerf blade. Blades with lower kerfs are called thin kerf blades. These blades are suitable for cutting dense material like aluminum.

Hook Angle

The hook angle of a tooth can be expressed as the inclination a tooth has. Imagine a vertical line between the center and the perimeter of the blade. If teeth are inclined forward, they are considered to have a positive hook angle.

In opposite cases where the tooth is inclined backward, it is called to have a negative hook angle. A blade with a negative hook angle, generally -5 to -6 degrees, is more suitable for cutting non-ferrous metals like aluminum.

Anti-Vibration Vents

Many blades have laser-cut vents on the blade body. This helps reduce the amount of vibration and heat created while cutting. As a result, the durability of the blade increases.

Disadvantages of Cutting Aluminum with a Table Saw

Tables saws are usually made for cutting wood. But if you use these for cutting aluminum or other non-ferrous metals, you will face some disadvantages like the following.

• The most dangerous hazard of using a table saw is kickback. Make sure the material you are cutting is aligned and clamped properly.
• Metal shavings can get splashed all over the workspace. Wear safety equipment before you start cutting.
• You might need to change blades frequently as they get blunt quicker when used on aluminum.

FAQs

Let’s find out answers to some commonly asked questions regarding the aluminum table saw blade.

What TPI is used to cut aluminum?

Aluminum sheets are generally very thin. The thinner the sheet, the higher the TPI will be. Generally, blades with 8 to 10 TPI are popularly used to cut aluminum.

Can carbide-tipped blade cut aluminum?

Many general-purpose blades are also carbide tipped, but you shouldn’t cut aluminum with those blades. Select a blade that is made for cutting non-ferrous metals.

Should I lubricate table saw blades?

If you lubricate your table saw blades, it will increase the working life of the blade by about 30%. It will also reduce the heat and vibration while cutting. So yes, you should.

Which lubricants to use with the blade?

The preference for lubricants varies from person to person. Generally, kerosene and rubbing alcohol are used as lubricants for cutting aluminum. You can also use WD-40, other mineral oils, or any general lubricants for aluminum.

How many times can I sharpen the saw blade?

Though resharpening won’t make the blade perform like new, you can still sharpen your saw blades 3 to 4 times before replacing them.

What should I use to protect saw blades from rusting?

You can apply a thin coat of WD-40 on your saw blade to keep it from rusting.

Final Thoughts

You might have become overwhelmed with the diversity of table saw blades. They come in many different sizes, shapes, and configurations. If you don’t choose the best table saw blade for cutting aluminum carefully, you are most probably going to make mishaps in your next cutting project.

To keep from that, the only way is to have an in-depth knowledge of table saw blades that are specifically made to cut aluminum and similar metals. And you have that here.