Sawzall blades are an essential tool for anyone who needs to cut through a variety of materials quickly and efficiently. But have you ever wondered what these blades are made of?
In this article, we’ll explore the different materials used to create Sawzall blades, including high-speed steel, bi-metal, carbide, and diamond grit. We’ll also take a closer look at the manufacturing process behind these blades and how they are designed to withstand the toughest cutting tasks.
So, whether you’re a DIY enthusiast or a professional contractor, read on to learn more about the fascinating world of Sawzall blades.
What Are Sawzall Blades Made Of
Sawzall blades are made from a variety of materials, each with its own unique properties and benefits. One of the most common materials used is high-speed steel, which is a type of steel that has been subjected to a tempering process that makes it more heat-resistant and durable. High-speed steel blades last up to five times longer than blades made from high carbon steel, which is the softest of the blade materials.
Another popular material used in Sawzall blades is bi-metal. Bi-metal blades are made by welding a thick strip of spring steel to a thin strip of hardened high-speed steel. The spring steel gives the blade flexibility, while the hardened steel keeps the teeth sharp. Bi-metal blades are designed to be faster cutting and longer lasting than other types of blades, and they can bend without shattering.
Carbide and diamond grit are also used in Sawzall blades. Carbide materials are extremely hard, heat-resistant, and impact-resistant, making them ideal for cutting thicker pieces of metal including cast iron, stainless steel, and high-strength alloys. Blades with an abrasive strip of tungsten carbide grit instead of metal teeth are often used for cutting dense materials such as ceramic tile, cement, brick, stone, and masonry. Diamond grit blades are used to cut concrete, glass, fiberglass, and ceramic, and can also cut fiber cement, cast iron, and masonry.
Introduction To Sawzall Blades
Sawzall blades are an essential tool for any cutting job, and understanding the materials they are made of is crucial for choosing the right blade for the job. Sawzall blades are made from a variety of materials, including high-speed steel, bi-metal, carbide, and diamond grit. Each material has its unique properties and benefits, making them suitable for different applications. High-speed steel blades are heat-resistant and durable, while bi-metal blades are designed to be faster cutting and longer lasting. Carbide and diamond grit blades are ideal for cutting thicker and denser materials such as cast iron, stainless steel, masonry, and concrete. Knowing the properties of each material can help you choose the right Sawzall blade for your next cutting project.
High-Speed Steel Blades
High-speed steel (HSS) blades are made from a type of steel that has been tempered to increase its durability and heat resistance. Compared to high carbon steel blades, HSS blades last up to five times longer. However, they are less flexible and more susceptible to breaking when bent.
HSS blades are ideal for cutting hardwoods, aluminum, and non-ferrous metals without excessive wear and tooth breakage. They are also suitable for cutting PVC, fiberglass, and other plastics. HSS blades are available in a variety of tooth configurations, including straight, wavy, and variable pitch.
One of the advantages of HSS blades is their ability to resist heat buildup during use. This makes them ideal for cutting materials that generate a lot of heat during cutting, such as metals. HSS blades are also resistant to wear and tear, making them ideal for heavy-duty applications.
Bi-Metal Blades
Bi-metal blades are a popular choice among professionals in the trades, auto yards, and other industries that require frequent or daily use of Sawzall blades. These blades combine a high-carbon steel body for flexibility and break-resistance, with high-speed steel teeth for heat-resistance, hardness, and durability.
One of the main advantages of bi-metal recip blades is their longevity. On average, they can last up to 10 times longer than a carbon steel blade. Although they may cost slightly more than HSS or HCS blades, they offer the versatility and toughness needed for more demanding applications. Additionally, bi-metal blades are recommended for DIY projects and occasional use due to their durability and long life.
In addition to the standard bi-metal blades, there are also versions that use a cobalt-steel alloy cutting edge. This provides even greater heat-resistance, wear-resistance, and overall longer blade life. These blades are suitable for a wide range of jobs including demolition (nail-embedded wood), auto dismantling, sheet metal and pipe cutting, as well as standard wood cutting.
Carbide Blades
Carbide blades are a type of Sawzall blade that is made with a carbide tip at the end of each tooth. This carbide material is extremely hard, heat-resistant, and impact-resistant, making it ideal for cutting through tough materials that would quickly dull or destroy other types of blades. Carbide blades can cut thicker pieces of metal, including forged iron, chrome steel, and high-strength alloys. They are the ideal choice for cutting metals that would soon destroy an HCS, HSS, or traditional bi-metal blades, such as grade 8 bolts and boron reinforced auto pillars.
Carbide blades are also designed to cut through dense materials like ceramic tile, cement, brick, marble, other stone, and masonry. Unlike traditional Sawzall blades that have teeth, carbide grit blades have an abrasive strip used for cutting these types of materials. The carbide grit’s hardness allows it to cut through these materials without damaging them or wearing them out prematurely.
Compared to other types of Sawzall blades, carbide blades offer 20 times the cutting life of a typical bi-metal blade. They are tough, heat-resistant, and impact-resistant, making them a popular choice among people in the trades, auto yards, and other professions that require more demanding applications. If you need to cut through tough materials quickly and efficiently without worrying about blade dulling or breakage, then carbide blades are an excellent choice.
Diamond Grit Blades
Diamond grit blades are a type of Sawzall blade that is designed to cut through hard and abrasive materials such as cast iron, hard tile, and masonry. These blades are made with a thick and rigid blade body that resists bending and fracturing, providing added durability. The diamond grit on these blades delivers up to 30 times longer life than standard blades, making them a cost-effective option for cutting tough materials.
One of the unique features of diamond grit blades is their precision diamond-grit size and placement, which provides fast cutting. Additionally, the TORCHTM SAWZALL® blade has a unique geometry that reduces blade twisting for straighter and more accurate cuts. These blades are equipped with 1/2 in. Universal Tangs that fit all SAWZALLS® for maximum versatility.
While diamond grit blades can cut through hardened steel, they are typically more expensive than other types of blades and can take longer to cut through the material. However, they are an excellent choice for cutting through abrasive and hard materials that may wear down other types of blades quickly.
Manufacturing Process Of Sawzall Blades
The manufacturing process of Sawzall blades involves several steps that vary depending on the type of blade being produced. For bi-metal blades, the process starts with a coil of flat stock that is unspooled into a machine that stamps the blades from the stock. A thick strip of spring steel is then welded to a thin strip of hardened high-speed steel to create the bi-metal blade. The blade is then ground and set for teeth before being manually hung onto automated tracks and sent through a machine for powder coating.
For Sawzall AX blades with carbide teeth, the process is different. The carbide welding and grinding process is done in an enclosed section of the factory that has access control. The teeth are made before the blade is cut out, unlike the typical Sawzall blade manufacturing process. After the teeth are welded onto the blade, it goes through a powder coating process and then UV printing where logos are printed on the blade. Finally, the blades are packaged with checks and balances to ensure the proper number of blades are placed in each pack.
Milwaukee Electric Tool’s engineers began looking for a new and better way to produce reciprocating saw blades in 1995. After five years of searching, they decided to combine AIDA-Dayton Technologies Corporation’s gap-frame press technology with automation and cellular manufacturing methods to create a manufacturing process with the level of automation required for Sawzall blades. Many details had to be worked out before equipment was even ordered, including integrating all the systems for the line and making sure they could communicate with a host network.
In conclusion, Sawzall blades are made from a variety of materials, each with its own unique properties and benefits. The manufacturing process involves several steps that vary depending on the type of blade being produced, but all involve precision and attention to detail to ensure high-quality and long-lasting blades.