Cutting Sandwiched Aluminum Sheet

[Tool_Freek]

I have a sheet of material that consists of
aluminum skins separated by a plastic core layer (unknown compound) between them. The aluminum skins are 0.028” thick and overall sheet is 0.23” thick. Having obtained this material from a salvage yard, I know nothing more about it.

Before investing in a special (nonferrous) 7-1/4” circular saw blade for my Skilsaw 77 worm drive, has anyone ever successfully circular saw cut sheet material of a similar construction before? If so, what blade did you use? Did the plastic core layer melt and cause problems? Did it tend to lift/peel the trailing aluminum skin (top) in the cut? Perhaps this material can only be sheared?

 

[gimpyrobb]

I have not cut what you are planning on cutting, but I would test cut a foot or so section with what you currently have.

I have cut 1/4 aluminum with my circular and it didn't do too bad, I was impressed.

Use hearing and eye protection!

 

[mike93lx]

I'd cut that with a regular wood blade without a second of hesitation

 

[y'sguy]

I have similar materials, and I have been able to cut them with several passes of a utility knife.
I have also cut them on my band saw and table saw. however, this will sometimes leave a ragged edge from the plastic. But, you can easily dress this off with a light sanding.

 

[kerrynzl]

I have a sheet of material that consists of
aluminum skins separated by a plastic core layer (unknown compound) between them. The aluminum skins are 0.028” thick and overall sheet is 0.23” thick. Having obtained this material from a salvage yard, I know nothing more about it.

Before investing in a special (nonferrous) 7-1/4” circular saw blade for my Skilsaw 77 worm drive, has anyone ever successfully circular saw cut sheet material of a similar construction before? If so, what blade did you use? Did the plastic core layer melt and cause problems? Did it tend to lift/peel the trailing aluminum skin (top) in the cut? Perhaps this material can only be sheared?

Straight cuts can be done with a knife/ box cutter [cut both sides] then snapped over an edge.
If the material is cool it snaps easy.

You can also use a router.
The edges clean up with a flap disc nicely [don't lean on it too much, be gentle]

 

[PCustoms]

I'd cut that with a regular wood blade without a second of hesitation

Fine tooth, wear good glasses and hearing protection. It will be loud and make a lot of slivers, but cut fine. Use a blade wax if you have it (Irish spring works too)

 

[mike93lx]

Fine tooth, wear good glasses and hearing protection. It will be loud and make a lot of slivers, but cut fine. Use a blade wax if you have it (Irish spring works too)

I bet stuff that thin between layers of plastic won't be that loud. Either way, PPE FTW

 

[PCustoms]

I bet stuff that thin between layers of plastic won't be that loud. Either way, PPE FTW

I was initially thinking a corrugated core, if solid I agree

 

[mike93lx]

I was initially thinking a corrugated core, if solid I agree

Even if corrugated, something that thin, especially damped by the plastic, won't "ring" as it's cut. Just a guess

 

[Beerhippie]

I cut aluminum plate up to 1/2" with my Skilsaw and a carbide wood blade all the time.

I worry with something like that that the blade might just snag and rip the **** out of it. Have you tried scissors? Big shop shears would seem to be dandy.

 

[The Cobbler]

 

[zimman]

Here's a idea. Get 5 pcs of paper and try to cut them all without a movement of the layers and report back. LOL
Good luck, we're all counting on you.
Zim

 

[The Cobbler]

Get 5 pcs of paper and try to cut them all without a movement of the layers

how does that relate to this question?

 

[Firebrick43]

Wabash National trailers is in town and they have trailers made of duraplate.

Its similar but made with 80k galvanized steel instead of aluminum and I have cut tons of it to line buildings and even one wall in my basement.

a 7-1/4 saw with a 24 tooth carbide wood blade cuts it just fine. Its loud and you want to wear long sleeves, eye glasses and a safety face shield but it cuts decent.

 

[zimman]

how does that relate to this question?

aluminum skins separated by a plastic core layer
How many skins, how many plastic core layers and are they held together.
Zim

 

[Firebrick43]

aluminum skins separated by a plastic core layer
How many skins, how many plastic core layers and are they held together.
Zim

2 skins and one core and they are all glued together

 

[zimman]

2 skins and one core and they are all glued together

Okay I'm out.
Zim

 

[The Cobbler]

How many skins, how many plastic core layers and are they held together.

there's an aluminum skin on either side, sandwiched with a core of plastic . very weather stable so it's used a lot in outdoor signs .

 

[Tool_Freek]

My thanks to everyone for your advice. It appears cutting aluminum with a circular saw and a carbide tipped wood cutting blade is worth a try. Seems odd though, afterall you eventually dull such a blade just cutting wood.

 

[Beerhippie]

My thanks to everyone for your advice. It appears cutting aluminum with a circular saw and a carbide tipped wood cutting blade is worth a try. Seems odd though, afterall you eventually dull such a blade just cutting wood.

After quite a long while with modern carbide blades.

Whatever you do, don't try the old trick for cutting sheet metal with a circular saw--reversing the blade. That works with an old school blade, but with a modern blade... picking the carbide chips out of your arms and legs gets tedious after a while.

 

[gazza]

I have been cutting ACP on an 8 foot long treadle guillotine for about 28 years, still does perfect cuts