Cutting aluminum

I have some aluminum. It's 1 1/2 inches in diameter. The outer layer is composed of 6 series aluminum and the inner is 7075. I've been going at it with a metal abrasive saw with a 14" aluminum oxide blade, which works well but notice that the blade is getting real hot causing the the inner and outer aluminum to attach to each other. What's the best way or a good way to cut aluminum. Open to any suggestions metal band saw, better type of blade, etc,...

most times when i get heavy aluminum to cut i use the skill saw with a carbide blade ,....you have to be carefull ,know how to use a circular saw ,and really really have good eye protection ,....it's tricky ,dangerous and dulls the blade ,but a good carbide blade will zip right threw aluminum ........disclaimer =....i often do things that would make an osha rep have a heart attack and often have to tell peaple "don't try this at home" ,....so use common sence

I've cut aluminum on the job with a regular carbide blade on a miter saw

I used plasma cutters, saw zaw and grinders with waffer disc that cut but were slow, crooked and sloppy. I prefer wood tools for long or many cuts( table, miter, or skill saw) I tried a 10 inch non ferrous blade($80) and was good not great. My best was a 3 pack of dewalt 7 1/4 skill saw blades from lowes used on table saw for sheet alum 1/4 thick. Use common sense and protection

use cutting oil to cool the blade

use a coarse blade, al is soft and when it heats up it clogs the teeth of fine blades

Carbide-tipped wood demo sawzall blade by Diablo. I used one to cut some similar stuff and it worked great! Recommended to me by someone here on the forum, but can't remeber who to credit.

A chainsaw to cut metal!!!??? That's ballsy. I like it. Ive hit a nail before with a chainsaw cutting fenceposts and came close to being casted in a Hellraiser movie...

chainsaws work great on lead, and ok for trailer house demo to cut the sheet metal, studs, etc. never tried aluminum. still kicks back though if not careful. Dont recommend using a new chain. Would use a chain you dont mind ruined.

I guess I am the odd man out here. My preferred method is diamond ceramic cutting wheels. You can get them from 4-10 inches. If they start plugging the abrasive tap it on rebar or mild steel. This cleans the abrasive and wears it to clean abrasive. If heat really becomes an issue use a tile / wet saw. just add a bit of WD40 of favorite oil to the water it pumps.

Originally Posted by etack

stihl makes a carbide tipped rescue chain of there saws.

Eric

I have heard people talk about titanium chains, not sure what they are meant for, just a random addition to the discussion

take a candle and use it like a crayon on the sawzall blade. this will prevent the aluminum build up on a metal blade. You will have to do this often; but after a few cuts and the blade still looks brand new you will find it well worth the trouble.

Originally Posted by bluemeate

this whole 'use common sense' doesnt help people without power tools experience

If they lack "common sense" I dont see what they are doing using power tools let alone without supervision. This is only a recipe for disaster, and it is never a matter of IF but of WHEN. Even though they are relatively safe to use, every time you pick up any tool, powered or otherwise you accept the fact you could be hurt, maimed or killed.

Just my $0.02 on it.