Cutting Aluminum

[JCLP]

Hello Foggers.
Looking to cut some 1/8" thick aluminum with my PS 300 EQ jigsaw. Would anyone have any recommendations on what blade and lubricant to use?
Thanks,
JC

 

[Richard A.]

When we thread aluminum electrical conduit, we use shaving cream (soap). Not cutting oil.

 

[Shane Holland]

You want to use one of the HS bi-metal blades.

 

[Cheese]

I've used 14-18 tooth bi-metal blades with a tooth profile designed specifically for metal cutting. Cutting 1/8" thick aluminum, I'd start with the 18 tooth blade, anything thicker and I'd start with the 14 tooth. You can always give it a shot of WD-40 from time to time, you don't need a lot.

It's better to error on fewer teeth when cutting aluminum because the chips like to weld themselves to the blade as the tooth count goes up. I've cut aluminum on a bandsaw with a blade that had too many teeth and it actually started to rip the teeth off of the blade.

 

[Holmz]

Having the speed low and the saw moving will get less heat into the material.
If the blade is going at it like a spring bunny, then it will heat it all up.

You want a tooth or two in the material, so 1/16 material require more than 16 teeth/" or use some ply as a backing board or top sheet.

What kind of alloy? (1100 is gummy, 6061, 2024 and 7075 all cut nice)

Have you considers routing it ?
Are making more than 1?
Is it straight or curved?
If it is straight have you considered a tracksaw?

 

[Discap]

One of the few good uses for WD 40

Bill

 

[Coen]

The blades suggested by Shane

Personally I hate using any lubrication when cutting anything, because it makes it messy.  [tongue]