Diamond Metal Cutting Blade

Experience with 4.5" and larger. Two negatives with handheld devices, the diamond area of the blades tend to break up if jammed or misaligned under power; face shield definitely needed. The other issue, diamonds burn up when heated so the blades do not last long without water cooling. Other than that, a 4.5" on a handheld grinder works wonders on many materials, I buy cheap blades as I expect to have them break up before they wear down.

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I don't do too much cutting with these discs, but I bought a 4.5" diamond wheel a few years back, and have not used an abrasive slicer since.

My diamond disc is a little thicker than my good abrasive wheels (Metabo was my favorite). The diamond seems to cut a little slower, but I'm not sure if it's actually slower, or if it's just my perception due to the fact that it throws fewer sparks since it isn't eroding. And also, abrasive wheels slow down as they shrink (since the edge speed decreases with diameter), while the diamond doesn't have this issue.

Dealing with Diamond Burning Issue

Anyway, I really meant to reply to the diamond burning up issue. While it is possible to burn up diamonds, that doesn't happen when cutting steel. By the time a diamond gets anywhere near the point of combustion, the steel will have already burned away long before (which coincidentally happens to be a good way to cut steel).

What does happen (and why surface grinders don't use diamond on steel) is that the steel actually bonds to the diamonds, shortening their life. But that's not the issue here.

Differences Between Metal and Stone Cutting Diamond Blades

Metal cutting diamond blades are designed differently than their stone cutting predecessors. The heat issue lies in how the diamonds are bonded to the plate. Stone cutting wheels run cooler. In fact, many water-cooled diamond tools are actually made from plastic! The air-cooled discs have spaces that pull in air, but such designs would kick back on steel, which is why really cheap diamond discs shouldn't cut steel.

What makes steel cutting diamond wheels special (read, expensive) is that they bond the diamonds in a way that is more heat resistant than the stone cutting wheels while still being able to be air-cooled.

Effectiveness of Tools on Aluminum

Abrasive cutoff wheels are also useless on aluminum. Aluminum buildup on abrasive wheels is a major cause of wheel explosions. I own a few aluminum-rated abrasive grinding wheels but do not recall seeing any aluminum-rated abrasive cutting wheels. Plus aluminum cuts faster with a jigsaw anyway.

About BoxcutterUSA's Offerings

Veteran Owned and Operated

BoxCutterUSA is owned and operated by JPhelps, LLC. We have been in the business of safety equipment sales since 1984. We are a veteran-owned company.

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We Prioritize Safety Above All Else

We are a veteran-owned business located in the Midwestern United States, offering high-grade cutting devices for needs both practical and commercial. Our products range from durable industrial-strength blades to light, pragmatic devices, all with a focus on safe application.

Our Cutters Save Money

Workplace lacerations threaten user safety and draw significant concerns from employers; Boxcutter USA provides low to zero-risk tools, which diminish the likelihood of injury to help maintain model environments. By replacing dangerous, exposed blades with a selection of multipurpose safety cutters, employers can expect fewer knife-related liabilities.

Industry Veteran

Our history consists of decades promoting and distributing safety products on an international scale. Boxcutter USA is at the cutting edge of safety.

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