Hacksaw blades come in all different sizes, shapes, and brands – it can be challenging to know what hacksaw blade you need! Craftsmen have used hacksaws for years because they allow cuts on job sites where power tools cannot go due to safety concerns.
There are, however, specific hacksaw blades used for cutting different materials, so attention to detail is needed when selecting the hacksaw right for your job.
To help ease the search process, the team at Cleaning King has put together this hacksaw blade guide that covers everything from choosing your hacksaw blade material to finding out when you should replace your hacksaw blades. Additionally, we’ll cover some information on the blades that should be used for different materials and why.
When choosing hacksaw blades, the main thing to look for is whether you need a metal hacksaw blade or a diamond-tipped hacksaw blade. These two choices will determine what type of material your hacksaw blades can be used on and how long they last.
Another critical factor in determining which hacksaw blades are right for your job is looking at the teeth per inch (TPI). This number determines how quickly and efficiently your hacksaws cut through different materials. It’s usually best to choose a higher TPI rating when cutting harder metals like:
In these cases, selecting from between 18TPI up to 30TPI should yield satisfactory results depending on how clean you want the hacksaw cut.
If the hacksaw is cutting softer materials like plastic or wood, then it’s best to select 12TPI up to 18TPI for hacksaws blades that are able to get through these types of material more easily and in a shorter amount of time.
TPI (teeth per inch / 25mm of blade)
Large profiles, aluminum, softer metals
General workshop projects
Steel plate up to 5/6mm thickness
Hollow sections and steel tubing
When considering all factors on which hacksaw blade would be most effective, make sure not to overlook your own skill level when making this decision.
If you’re an experienced metal cutter with plenty of practice under your belt, chances are selecting from between 25TPI up to 30TPI will work well since they require less effort by hand while still getting through harder metals quickly without sacrificing quality.
On the other hand, if you’ve never used hacksaws before, hacksaw blades between 15TPI up to 18TPI are a great choice because they require less effort on your part and will still get through metal smoothly.
The best overall hacksaw and hacksaw blade brand is the Lenox brand. They are made in the USA, and they’re known for their incredible hacksaw blade durability. Some other leading hacksaw blade brands include:
The Lenox High-Tension Hacksaw, for example, has a unique I-beam design that allows blades to tension up to 50,000 psi, resulting in fast, straight cuts. Even in damp and chilly environments, the rubberized handles allow for confident handling.
The Lenox hacksaw blades may be used as a jab saw and stores up to 5 extra 12-inch hacksaw blades in the I-beam. All hacksaws include one 12-inch 24 TPI hacksaw blade for immediate use.
Another great hacksaw brand is the Craftsman hacksaw, which also offers blades that will cut through metal like butter! The only downside to this brand is it does not include any guides or clamps with its products.
Hacksaw blades can survive for months, even a year, before needing to be replaced or upgraded.
Depending on the materials you use the blades on, the hacksaw blade may need to be replaced sooner rather than later.
The most common type is the standard hacksaw that has a metal frame with an adjustable blade clamping system on each side. Some other types include hacksaws that are foldable or come with ergonomic handles to reduce fatigue while cutting through metals over extended periods of time.
If you’re using your hacksaws frequently in construction work, then it’s best to go ahead and get the more expensive high-quality hacksaw blade brand like Lenox. These blades will last much longer than cheaper brands which means you won’t have to change them out as frequently.
A 14 TPI blade is ideal for aluminum. At Cleaning King, we like to recommend MK Morse when it comes to the best metal cutting blade manufacturer. Look for a carbide-tipped blade with at least 8 TPI if you’re cutting cast iron, stainless steel, or high-strength alloys, or if you do jobs such as car dismantling and fire rescue.
MK Morse is a brand to consider when looking for hacksaw blades because of their metal cutting abilities and high-quality construction. These hacksaw blades are very high-quality steel that can cut through all types of metals and materials with ease.
These hacksaw blades are better to use in construction work where they will be used often than buying cheaper brands which would need to be changed out more frequently.
The MK Morse brand is worth looking into when it comes to the best hacksaw blade manufacturer due to their ability to have carbide-tipped blades ranging from 14 TPI – 332 TPI, making them ideal for cutting:
The stand out features of the MK Morse Hacksaw Blades include:
The team at Cleaning King would recommend the MK Morse 14 TPI hacksaw blade for any aluminum cutting project.
Hardened steel cutting may be a time-consuming and even hazardous operation. Knowing which strategies for cutting through-hardened steel are most effective can save a lot of time, effort, and aggravation.
For hardened steel, we would recommend a hacksaw blade with a bi-metal construction. Look for at least 18-24 TPI for hardened steel projects.
When working with thinner metals, such as sheet metal, it is essential to have a finer cut. Bi-metal blades with an 18-24 TPI Cutting thin metals, including sheet metal, necessitates a finer cut. Use 14-18 TPI bi-metal blades for thicker metals like steel pipe, angle irons, and tubing.
The best hacksaw blade for cutting hardened steel is the Lenox Tools Hacksaw Blade, 12-inch, 18 TPI, 2-Pack.
The stand out features of the Lenox 12-inch Hacksaw blade include:
The team at Cleaning King highly recommends the Lenox 18-24 TPI hacksaw blades as some of the best on the market for cutting hardened metals.
The best hacksaw blade for cutting stainless steel is a blade with 24-32 TPI. Hacksaw blades made of bi-metal are ideal for cutting. They cut a wide range of metals, including unhardened tool steel and stainless steel.
The Lenox Tools Hacksaw Blade, 10-inch, 24 TPI, 10-Pack, is our number one pick for stainless steel cutting hacksaw blades.
The Lenox hacksaw blade is perfect for any job involving hardened materials because it cuts through all objects effectively without leaving burrs behind. These blades are bi-metal, which makes them durable and effective hacksaws for cutting stainless steel.
The Lenox hacksaw blades are bi-metal and feature a spring steel body and a high-speed steel cutting edge. The blades may bend and flex without shattering due to the high-speed steel, which provides longer life.
The Lenox blades are designed with the ‘Lenox Tough Tooth Design’ to help avoid tooth strip pages. These blades work with both Lenox hacksaw and other hacksaw frames on the market.
The team at Cleaning King highly recommends the Lenox 24-32 TPI blades for projects that involve stainless steel cutting.
The best hacksaw blade for cutting wood is one that is 6-10 TPI. The best hacksaw blade for this type of cutting is the Starrett Redstripe solid high-speed steel power hacksaw blades.
The Starrett hacksaw blade has a 0.335 pinhole diameter, making it easy for users to attach it using the C-clamp method on their hacksaw, without any loss of its quality and power as increasing productivity with quickened work speeds.
The Starrett Redstripe Hacksaw Blade also features High-Quality materials and construction that guarantee you maximum durability even after years of continuous use!
They are constructed of a solid, fully hardened molybdenum high-speed steel composition for long-lasting performance and efficient cutting action with high feed pressures to effectively cut hard alloys like stainless steel.
These blades are capable of cutting other materials like metal, plastic, rubber, and wood. They are heat-treated to increase performance by retaining optimal cutting hardness. It will not fit in smaller-sized hacksaws (for example, 12 TPI). These blades can be used to reduce friction while doing clean cuts quickly because they do not require facing or lubrication during operation.
The Team at Cleaning King highly recommends the Starrett Redstripe 10 TPI hacksaw blade as the best for projects involving woodcutting.
The overall best hacksaw blade for cutting metal is the Lenox 24 TPI hacksaw blade.
The Lenox hacksaw blade features a high-grade alloy steel construction and is also corrosion-resistant.
Lenox hacksaw blades are ideal for cutting metal because they do not require lubrication during operation and come with teeth that minimize the amount of heat generated while sawing through metal.
The Lenox Tools High-Tension Hacksaw has an advanced tension control that will let you make clean, strong cuts in bars and metal thresholds. For making crisp, clean cuts with 12-inch saw blades, turn the tension knob to increase tension up to 50,000 psi.
This hacksaw’s sturdy frame and rubberized, secure-grip handle make it one of the finest overall hacksaws for most users.
The saw is about 1.6 pounds and strong enough to cut metal. It has one blade with 24 teeth per inch (TPI) and can store five blades in the handle, making it ideal for metal cutting. When combined with a 6-inch Lenox reciprocating blade, the Lenox saw becomes a jab saw.
The team at Cleaning King highly recommends the Lenox brand as the best overall brand for hacksaw blades, including those used for metal cutting.
Cutting metal with a hacksaw can be an intense and often dangerous process. The hacksaw blades should be kept sharp and in good condition to ensure the sawing is done safely.
One of the most important steps when cutting metal with a hacksaw blade, which can easily be overlooked, is assembling the hacksaw correctly before use. This process ensures that users will get optimal performance from their hacksaws and prevent accidents from occurring.
The hacksaw frame should be held firmly in place. The hacksaw blade must then be placed into the hacksaw frame and tightened by turning it clockwise, which is opposite to how screws are turned for safety purposes.
Hacksaws need to stay sharp, so they can effectively cut through metal without getting stuck or breaking apart. Regularly rinsing hacksaw blades with water and oiling the frame is a great way to keep hacksaws in good condition.
Hacksaws should never be left sitting in water because this will cause them to rust more quickly. It also corrodes hacksaw frames over time as well as dulls the blade itself. Instead, after each use, hacksaws must have their teeth dried off using a dry cloth or paper towel before being stored away until next time.
The right hacksaw blade for metal cutting will be one that is right for the material that needs to be cut. The hacksaw blades are made out of different materials, including carbon steel and high-speed steel.
Carbon Steel hacksaw blades should be used on metal cutting applications that do not require precision or accuracy because they cannot stay sharp very long.
High-Speed Steel hacksaw blades can stay sharp longer and are ideal for metal cutting.
Another thing to consider when choosing hacksaw blades for metal cutting is the number of teeth per inch (TPI) it has. The higher the TPI hacksaw blade, the smoother and more precise the cut will be. However, this also means that you need fewer strokes because there are fewer gaps between each tooth.
The correct TPI for Metal cutting is:
When cutting through thicker material out of metal using hacksaw blades, having an increased TPI can help reduce hand strain.
When cutting metal, wear eye protection and gloves at all times. This gear will protect you from the sharp ends of freshly cut metal.
Prepare the workpiece by clamping it in place securely so that you can cut with little effort.
When using hacksaw blades for light metal cutting tasks, always use your arm rather than bodyweight to apply force while pushing through the material being cut.
When doing heavier material removal or working on overhead projects, secure yourself with an appropriate support structure so that both of your arms are free to power through each stroke without straining anything but the hacksaw blade itself!
To begin the cut, make a series of one-way strokes in the direction of the teeth to create a narrow incision that the blade can sit in. Once the blade has cut into the metal at least one millimeter or two, it will be able to saw completely forward and backward.
When cutting, try not to rush; use a slow, consistent sawing motion to get the best cut and minimize the chance of the blade overheating and breaking. To reduce friction, use a little bit of machine oil or cutting fluid on the blade.
The TPI of your hacksaw blade is the main thing that differs when cutting different types of metal. A hacksaw blade with a higher TPI will cut through metal faster than one with fewer teeth per inch. If you are cutting thicker pieces of metal, it is best to use blades that have more teeth, so the hacksaw does not overheat and break. For thinner metals, fewer Teeth Per Inch (TPI) can be used without overheating.
The best way to brace metal for cutting is to use hacksaw horses. They are sturdy enough to support the metal, regardless of where it is being cut. This can allow you to focus on making a precise slice through the metal’s surface instead of holding onto something that could slip or move at any moment.
Use clamps for larger pieces of metal. This will ensure that the metal does not shift or move when cutting.
When you are working with thin pieces of metal, it is possible to cut them without bracing at all by holding onto them yourself. However, this can be dangerous and lead to slippage or cuts in your skin. Instead of using hacksaw horses for smaller metals, place a piece of scrap wood on top of the hacksaw horse so that they do not slip off while cutting.
Here are some of the most frequently asked questions about cutting different materials with a hacksaw, the details of hacksaw blades, and what goes into choosing the right blade.
Hacksaws can cut through various materials, including steel.
However, depending on the size of metal you are cutting and what blade is in your hacksaw, it may or may not be challenging to do so. To choose the correct blade for cutting steel, look at the TPI of the blade.
If the blade has a low TPI, it will not be able to cut through steel. You’ll want to choose a hacksaw blade with at least 20 TPI for cutting metal like steel and stainless steel.
Changing hacksaw blades is easy and can be done in a matter of minutes.
You should replace hacksaw blades when they become dull. Hacksaw blades typically last for ten to twenty uses. When hacksaw blades are replaced, the blade tension may need to be checked once more.
To prolong hacksaw life, keep them clean and store them inside their carrying case for protection from debris and dust buildup between uses.
To tension, a hacksaw blade, start by removing the hacksaw blade from the saw frame.
Next, add a hacksaw tensioning tool to hold the hacksaw blade in place while tightening it onto its frame. With both hands on either side of your hacksaw frame’s screw head and on hand behind the hacksaw handle for control, tighten down a wing nut until you feel resistance or until it is very tight against a hacksaw blade that has been secured into position using a hacksaw tensioning tool.
Make sure not to over-tension your metal cutting hacksaws, as this can cause them to snap during operation.
If you are struggling to make hacksaw blades sit in line together, there may be an issue with the tensioning tool itself – check whether it is the correct size for your blade. If not, then use a different hacksaw frame when tightening down hacksaws into place using this tool.
When finished cutting through metal materials with your hacksaw blade, release its tension using your hacksaw’s wing nut before removing and replacing any old blades that no longer work as they should. Replace them immediately if their teeth appear worn or bent out of shape because one might snap during operation sooner rather than later.
At Cleaning King, we recommend the Lenox brand hacksaw blades as the overall best blades on the market. The Lenox brand offers hacksaw blades in various sizes with a variety of cutting edges.
For more than a century, Lenox has provided high-quality tools that deliver exceptional performance. Their unique depth of knowledge in the field of cutting technology and performance allows us to understand it better than anyone else. They put this power to work for you by developing equipment that makes your job easier.
The hacksaw blades from Lenox offer such a wide range of cutting edges, including hacksaw blades with both bi-metal and high-speed steel teeth.
While you may find hacksaws on construction sites or in metal fabrication shops, they can be used for any number of things around your home and office. With so many options available for hacksaw blades from Lenox, we recommend using them as one of the best tools for whatever project you need them for.