Bandsaw Blades for Cutting Metal - Choosing the best one

In Partnership with BAHCO

• Why blade material matters: matching blade type to workpiece hardness, volume, finish and cost-per-cut.

• Bi-Metal blades: how high-speed steel teeth welded to a flexible steel back deliver long life, clean cuts and versatility. We’ll spotlight BAHCO’s Sandcut® range and the Easy-Cut Xtreme tri-metal upgrade.

• Carbide-tipped blades: why tungsten-carbide teeth excel on hardened and abrasive alloys. Get the lowdown on BAHCO’s Carbide Triple Set® TSX, TCZ and THS Multi Set lines.

• Selection & maintenance best practices: feed rates, lubrication, tensioning and tooth pitch tips to maximize blade life and cut quality.

Selecting the wrong blade can dramatically increase cutting time, wear, and cost per cut. Softer carbon‐steel blades wear out quickly on hard metals, whereas purpose-built bi-metal and carbide blades offer the hardness, toughness and heat resistance needed for most ferrous and non-ferrous applications. In production or foundry settings, cost per cut and downtime for blade changes are critical; premium blades often pay for themselves through extended life and fewer secondary operations.

Bi-Metal

Bi-metal blades combine a high-speed steel (HSS) cutting edge with a flexible alloy-steel backing, merging hardness and toughness in one blade.

Key features & benefits

• HSS tooth edge: Maintains sharpness and resists heat up to ~600 °C, for clean cuts in stainless, tool steels and high-volume work.

• Flexible backing: Absorbs bending stress around drive wheels, preventing premature breakage.

• Versatility: Ideal across round bars, tubing, profiles and complex contours, from mild steel to mid-hard alloys.

• Cost-effectiveness: Longer life than carbon-steel blades and lower cost-per-cut than carbide in general-purpose cutting.

Best practices for Bi-Metal blade use

1. Tooth pitch selection: Use coarse pitch (e.g. 2 TPI) on large section cuts; finer pitch (8–14 TPI) on thin or hard materials.

2. Lubrication & cooling: Always flood the cut zone with cutting fluid to reduce heat and extend tooth life.

3. Proper tensioning: Follow machine manufacturer’s specs; under-tensioning leads to tracking issues, over-tensioning to breakage.

4. Feed rate control: Match feed to blade width and TPI—too aggressive leads to tooth stripping, too light to rubbing and heating.

Carbide-Tipped

When you need to cut hardened, abrasive or exotic alloys, carbide-tipped blades deliver unmatched durability. Each tungsten-carbide tooth is brazed to a steel back, combining extreme hardness with band flexibility.

Key features & benefits

• Superior wear resistance: Carbide holds an edge up to 1,000 °C, ideal for high-volume or abrasive materials like stainless, titanium, nickel-based alloys and cast iron.

• Clean, fast cuts: Positive rake angles and multi-chip grinds reduce cutting forces, lower vibration and improve finish.

• Extended blade life: Outlasts bi-metal by 5–10× in tough alloys, cutting downtime and secondary finishing.

Best practices for Carbide blade use

1. Start-up feed: Begin with a light feed to break the carbide into the cut, then gradually increase to the optimal rate—carbide chips best at consistent, moderate feeds.

2. Maintain coolant flow: Carbide can tolerate heat, but proper cooling prevents work-hardening of the cut surface.

3. Inspect teeth regularly: Look for chipped or cracked tips; replace before damaged teeth affect the entire run.

4. Use appropriate blade width: Wider blades ( ≥ 1 ⁄ 2″) on large sections to prevent deflection; narrow blades ( 3 ⁄ 32″–1 ⁄ 8″) on tight-radius or thin work.