Abrasive Saw on Cast Aluminum

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I hope I am not bringing up something that has already been explained. I did some searching, but don't know if I am searching for the right thing.I have a 14" HF cut off saw with an abrasive disc. Someone is sending me a throttle body that is cast aluminum that they want chopped in half, then welded together.I've been reading and watching videos on cast aluminum and just wondering if using an abrasive disc is going to be an issue beyond the underlying issues.I guess more specifically, and let me know if I am overlooking anything, am I going to have to deal with a bunch of abrasive crap in my cast aluminum?
Reply:Aluminum cuts nice with a (wood cutting) chop saw or a table saw No grinding dust.Dave J.Last edited by MinnesotaDave; 05-08-2013 at 10:13 PM.Dave J.Beware of false knowledge; it is more dangerous than ignorance. ~George Bernard Shaw~ Syncro 350Invertec v250-sThermal Arc 161 and 300MM210DialarcTried being normal once, didn't take....I think it was a Tuesday.
Reply:Alum has a tendency to load up grinding wheels, and I'm sure the abrasive blade will be no exception. I'm not exactly sure what the abrasive blade is made up of off the top of my head, but alum oxide would be my 1st guess. Alum oxide is the stuff you want to remove off of alum so you can weld it, so embedding the surface with alum oxide when you cut it would mean you'd still have to file or machine the surface to remove all the contaminants you just added. My 1st thought would be a band saw. 2nd thought would be some sort of carbide toothed blade..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:Originally Posted by just_some_dudeI hope I am not bringing up something that has already been explained. I did some searching, but don't know if I am searching for the right thing.I have a 14" HF cut off saw with an abrasive disc. Someone is sending me a throttle body that is cast aluminum that they want chopped in half, then welded together.I've been reading and watching videos on cast aluminum and just wondering if using an abrasive disc is going to be an issue beyond the underlying issues.I guess more specifically, and let me know if I am overlooking anything, am I going to have to deal with a bunch of abrasive crap in my cast aluminum?
Reply:It will cut it but you will have to grind out the cut afterwards to get a decent weld. A sawzall, hacksaw, table saw like mentioned, or any bladed saw would be better if you have one.
Reply:hmm... thanks for the replies so far. All I have is the abrasive saw. I was wanting to order a Freud Diablo blade (for metal) for it, but from reading seems like the abrasive saw is rotating too fast.Haven't considered a wood blade for it, I'd have to look into that.Looks like at this point I should just consider buying a different saw? Sounds like a dry cut metal saw would be the next move? I've always thought a radial saw would come in handy, would that be acceptable?Last edited by just_some_dude; 05-10-2013 at 03:26 PM.
Reply:A radial arm saw is not what you want for cutting aluminum. You would have to clamp the work down and feed it in the opposite direction. A table saw is vastly superior, especially with a sled. I also use a Skilsaw with carbide blade. And a Sawzall can do a pretty fair job but leaves a rough surface.
Reply:Yeah, I guess one of my concerns is I need a straight cut. My welding skills are still quite novice and welding pipe back together, for me so far, has not been very successful. Mostly because my cuts were at an angle and I could not get the pipe flat against itself. Also, welding gaps gets a bit questionable for me (at this time). The HF abrasive saw seems to cut okay once the wheel is down to about 5 inches . Still, dealing with the abrasive in the already cast aluminum... rather just get a new saw .The throttle body and manifold are all one piece, cutting it to turn the body and weld back together. That part of the throttle body is round.
Reply:Originally Posted by just_some_dudeYeah, I guess one of my concerns is I need a straight cut. My welding skills are still quite novice and welding pipe back together, for me so far, has not been very successful. Mostly because my cuts were at an angle and I could not get the pipe flat against itself. Also, welding gaps gets a bit questionable for me (at this time). The HF abrasive saw seems to cut okay once the wheel is down to about 5 inches . Still, dealing with the abrasive in the already cast aluminum... rather just get a new saw .The throttle body and manifold are all one piece, cutting it to turn the body and weld back together. That part of the throttle body is round.
Reply:Provided you can carefully mark a cut line, you might not even need a power tool. A hacksaw could do it. But I wouldn't hesitate to use a Sawzall. Just get set up comfortably, where the part is immobile and in a position that makes it easy for you to see the cut line; cut from 4 sides so the depth of each cut can be shallow.Surely you don't need to go out and buy a new tool to do this.
Reply:duplicate
Reply:Would one of these be big enough to cut it? Because I guarantee you, you'll find plenty of uses for it elsewhere, if you're a welder/fabricator.I use mine all the time ... and I almost never use my abrasive chop saw anymore, because this does a way better job in a small fraction of the time.http://www.ebay.com/itm/Milwaukee-62...-/290875542503
Reply:I would also worry if the same abrasive blade has been used for steel.  Iron oxide (rust) + aluminum  = thermite.You might end up with more excitement than you bargained for.