What do you use to cut aluminum?

[DaveA]

I've got some 2024T and 6061T stock that I need to whack up for some projects coming up, and was wondering what type of saws you x-spurts would use. I'm relegated to a chopsaw/miter saw setup for now. What would you use??
Your experiences and suggestions, please!
DaveA

[wsuwrhr]

I use a variety depending on the job/time I have.
My bad boy is a Dewalt chop saw with a carbide tipped blade. Goes through like butter when you keep the blade lubed, goes through teeth like butter when you don't....
For sheet I use a Skilsaw with a carbide tipped blade. Definitely don't either method without safety glasses AND hearing protection.
For production runs I use a bandsaw or buy it already cut from a Remnant shop.
You didn't give and description to what size you were cutting so it is hard to say what is best for what you are doing. I hope this helps.
Brian
above tips are for ideal closed course condtions, please do not try them at home or around small children. Use ideas at your own risk.
[ June 02, 2003, 09:43 PM: Message edited by: wsuwrhr ]

[GofastRacer]

For rough cutting lengths of extrusion, I use a chop saw but for making brackets, motor plates etc, I use a bandsaw then sand the edges close and let the polisher take care of the rest!. BTW, 2024 is soft, use 6061, also if you annodize it, you will get two different shades between the two alloys!.. :)

[wsuwrhr]

GofastRacer:
For rough cutting lengths of extrusion, I use a chop saw but for making brackets, motor plates etc, I use a bandsaw then sand the edges close and let the polisher take care of the rest!. BTW, 2024 is soft, use 6061, also if you annodize it, you will get two different shades between the two alloys!.. :) yea what he said, I left that out, but take it into consideration.
Brian

[Stab-n-Steer]

GofastRacer:
For rough cutting lengths of extrusion, I use a chop saw but for making brackets, motor plates etc, I use a bandsaw then sand the edges close and let the polisher take care of the rest!. BTW, 2024 is soft, use 6061, also if you annodize it, you will get two different shades between the two alloys!.. :) Beg to differ Gofast, but 2024 is harder than 6061 and actully cuts and machines better. The "gummy" alloys are 3003(dead soft), 5052, and 6063... Use some good cutting/tapping fluid like Tapmatic #2 and it will cut great on a carbide chop saw...
S&S

[058]

Hey S&S, Long time no chat, how are ya? Are you going to CFW on Father's day? I'll be there on Sat. only. Just so I don't get accused of hijacking the thread, Tapmatic is good shit and will allow you to cut just about any aluminum. I wouldn't be without it. 2024 alum. is one of the most popular hi-strength alloys available. It is easily machined to a high finish and easily formed in an annealed condition and can be heat treated. It has a low resistence to corrosion and should be annodized. Wanna know more? :D

[Stab-n-Steer]

Hey 058,
Doubtful on CFW... Got multiple graduations to attend on Saturday, Sunday's my only shot. Just got back from Laughlin, nine hour drive. Great event but it's the hottest damn place I've ever been burningm Now we need to get ready for Burley.
Gofast is correct about the anodizing, all alloys will take on a different shade. When you weld aluminum that will be anodized you have to select the correct rod or the weldment will turn almost black when anodized.
Tapmatic is great stuff and the nice thing is that you can get it almost anywhere, like Orchard Hardware...
S&S

[schiada96]

058 and s&s have it right. Miter saws work great for lube use stick wax or a bar of soap will work.
4000 watt laser will also work.

[GofastRacer]

S&S, 058 you're right, my bad got my FKN numbers mixed up! :mad: I been using Tapmatic for a long time, some good stuff!. schiada96, you say stick wax for cutting, I've never used it, how does it work for milling?.. :confused:

[superdave013]

I was cutting with this last night. :D
http://www.v-driveboat.com/images/gallery/photos/55_Dsc01017.jpg

[LeE ss13]

Anybody ever work with 7075 ??? First time I tried to drill a hole in some, I thought it must be steel in disguise !!!

[GofastRacer]

LeE ss13:
Anybody ever work with 7075 ??? First time I tried to drill a hole in some, I thought it must be steel in disguise !!! You're right, it is very hard stuff!.

[GofastRacer]

superdave013:
I was cutting with this last night. :D
http://www.v-driveboat.com/images/gallery/photos/55_Dsc01017.jpg What are you making now??.. :D :D
[ June 03, 2003, 08:33 AM: Message edited by: GofastRacer ]

[Stab-n-Steer]

GofastRacer:
S&S, 058 you're right, my bad got my FKN numbers mixed up! :mad: I been using Tapmatic for a long time, some good stuff!. schiada96, you say stick wax for cutting, I've never used it, how does it work for milling?.. :confused: Very messy! I use stick wax for the band saw but for milling, drilling and tapping use a fluid like Tapmatic.
S&S

[burbanite]

We use 6061 on all of the ordinary everyday stuff and it is weldable.
2024 on some structural components but invariably we use 7075 as most of these things are highly stressed, welding not recommended with these two.
Cutting blanks is usually done in our automatic cutoff saw (wet lubed) or the bandsaw with DoAll Tool Saver (wax like substance in a cardboard tube applied to the blade while running).

[Backfire]

I use a big Makita angle grinder fitted with a carbide metal-cutting blade. I have to be VERY careful to cut straight because if the blade gets crooked and bites at 10,000 rpm, the blade can explode or the thing can take off and makes quite a mess of anything that gets in it's way before it stops (The damn has bit me on the back of the left hand twice)

[schiada96]

A word of advise on working with 7075 be careful when drilling holes this material tends to climb up drills if not clamped.
7075 is tuff material in a pinch we use it to make staming dies.

[DansBlown73Nordic]

idea A Chain Saw????? eek!

[GofastRacer]

schiada96:
this material tends to climb up drills if not clamped.
Man, you got that right!.. eek!

[GofastRacer]

Stab-n-Steer:
GofastRacer:
S&S, 058 you're right, my bad got my FKN numbers mixed up! :mad: I been using Tapmatic for a long time, some good stuff!. schiada96, you say stick wax for cutting, I've never used it, how does it work for milling?.. :confused: Very messy! I use stick wax for the band saw but for milling, drilling and tapping use a fluid like Tapmatic.
S&S Kinda thought that, that's why I asked. guess I'll stick with Tapmatic!... :cool:

[schiada96]

You guys talk about tapmatic they also make a stick lube called edge lube. works great for sawing and grinding. It turns to dust with a easy clean up. It's not for milling.