Aluminium is one of the lightest metals, and we come into contact with it almost every day in various areas of life. It owes its popularity to its exceptional ductility, and cutting aluminium can be done in a variety of ways. Read our article and find out about the most necessary tools for this purpose.
Aluminium is one of the lightest metals, and we come into contact with it almost every day in various areas of life. It owes its popularity to its exceptional ductility, and cutting aluminium can be done in a variety of ways. Read our article and find out about the most necessary tools for this purpose.
Features of aluminium
Aluminium is a chemical element that occurs naturally in the earth’s crust. Pure aluminium is rarely used due to its low strength, so using alloys has proven to be an excellent solution to achieve the desired effect. The main properties of aluminium are:
- high ductility,
- low density, making it one of the lightest metals,
- good thermal and electrical conductivity,
- resistance to water, nitrogen compounds and some organic acids
- not resistant to sea water, mercury ions, anaerobic acids and hydroxides
Uses of aluminium. Why would you cut aluminium?
Due to the above-mentioned properties, aluminium is suitable for a variety of uses. Its ductility makes it easy to process both hot and cold, and therefore very universal. The main processing methods are:
- rolling (e.g. of foil and pipes),
- extrusion (e.g. sections and rods).
Aluminium and its alloys have gained immense popularity in various industries:
- food (e.g. for the production of cans, caps, aluminium foil),
- catering (e.g. for the production of baking sheets and cake molds, elements of kitchen appliances)
- cosmetics (e.g. for the production of aerosol packaging)
- chemical (e.g. for the production of chemical tanks, vacuum dryers),
- construction (e.g. for the production of windows, gutters, eaves, air conditioning ducts)
- automotive (e.g. for the production of car bodies, wheels)
- nautical and shipbuilding (for building elements of boats and ships)
- aviation (for the construction of aircraft components)
Such a wide range of applications proves its practical properties. However, in order for aluminium to fulfill its task, it needs to be processed. We will focus on one method of processing, i.e. cutting, later in this article.
How to cut aluminium
Various tools can be used for this purpose. You should choose the tools in terms of the required precision of work, as well as where it will be performed. Cutting aluminium, just like cutting plexiglass, can be carried out both at home and in a professional workshop.
Cutting aluminium – methods
Before you start working, you first need to decide whether you want to work with a handy tool (e.g. a jigsaw or miter saw equipped with special blades) or use a method that requires more advanced skills and equipment. These include plasma, laser and even… water cutting. Each of these methods is briefly described below.
Plasma cutting of aluminium sheets
This is considered to be a very precise method. Aluminium is an excellent electric conductor, so it is cut with a plasma arc. The plasma cutters used for this method produce extremely smooth edges. However, this method is not for everyone, so unless you are experienced with the method you may want to use the services of professionals.
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Plasma Cutter – 85 A – 400 V – pilot arc
519.00 GBP479.00 GBP -
Plasma Cutter – 55 A – 230 V – 17 mm
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Plasma cutter with compressor – 40 A – ED 60% – Digital – 230 V
399.00 GBP249.00 GBP -
CNC Plasma Cutter – 85 A – 400 V – pilot arc 499.00 GBP
Laser cutting of aluminium
The same applies to laser cutting. It requires the use of a special laser, preferably with precision given in micrometers. The laser beam and technical gases make it possible to achieve an exceptionally clean and accurate cutting line. Aluminium laser cutting takes place in industrial conditions. Companies offering such services also offer cutting of other materials, incl. sheets of carbon steel and stainless steel, brass and copper.
Water cutting of aluminium
Water cutting is based on the use of equipment that combines the functions of a cutting machine and a high-pressure pump, where a stream of water under sufficiently high pressure (even 3800 bar) mixed with an abrasive material is able to cut or shape the processed material. Water cutting is used not only for aluminium, but also steel (including stainless steel), non-ferrous metals and plastic. It always takes place in industrial conditions.
Although it requires investing in very expensive machines, it has a number of advantages. It is suitable for materials of different thickness. In addition, it practically doesn’t generate waste or cause damage to the treated material (e.g. deformation) thanks to the use of kinetic energy. It also doesn’t produce dangerous fumes.
Cutting aluminium – popular tools
If you don’t want to outsource aluminium cutting to a professional company, and you enjoy DIY and have the necessary tools, you can try to cut aluminium yourself. If you don’t require a high degree of precision, but only want to cut the metal, handheld equipment will be sufficient. Angle grinders, circular saws and jigsaws are most often used for this purpose.
Angle grinders
An angle grinder works well for cutting aluminium, provided that a special cutting disc designated for aluminium is used. Abrasive discs (e.g. corundum and diamond discs) may turn out to be insufficient and even dangerous. When processing aluminium, it is essential to remember about personal protective equipment: goggles, gloves and a long-sleeved top. An angle grinder is a good tool for DIY enthusiasts who cut aluminium sheets from time to time.
Circular saws
A circular saw is a universal tool used in various types of workshops. It is also suitable for cutting aluminium, but as with an angle grinder, you should choose a blade designated for aluminium. A circular saw is not only good for using with sheet metal, but also profiles and pipes. It can be used for precise work, and is comfortable to use.
Jigsaws
Another convenient piece of equipment suitable for cutting aluminium is a jigsaw. In this case a suitable saw blade must be used. When choosing a specific model, it is worth paying attention to whether it is suitable for cutting aluminium and the maximum thickness of the sheet.
Cutting aluminium – summary
Cutting any material requires the use of appropriate tools. The situation is no different in the case of aluminium. As you already know, there are various methods and equipment for cutting aluminium, which can be used by both DIY enthusiasts and professionals. The choice of technique depends mainly on the amount of metal to be cut as well as the precision required.
Professional methods are used in industry, usually on a large scale. These include laser and water cutting of aluminium using special machines. Such processes are also used in welding, but with the use of plasma cutters. In home conditions, if you need to cut a piece of aluminium sheet, an angle grinder or a jigsaw will be ok, as long as you use a blade intended for aluminium. If you process non-ferrous metals in your workshop, read our next article about polishing aluminium
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