Diamond Saw Blade Types - how do I choose? - Aussie Sapphire

Have had a few questions recently about the different types of saw blades so thought it worth a post.
Essentially, there are three main types of diamond saw blades used in the lapidary field – all have their pros and cons.

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A) Sintered Blades

Sometimes referred to as Continuous Rim Blades, these blades are more expensive but tend to be longer lasting and offer better performance. Sintered blades are made embedding diamond particles in a metal bond around the rim of the blade – the diamond extends through the full depth of the rim and so as the metal bond rim wears away, new diamond particles are exposed and keep the blade cutting.

These blades are available in premium or economy versions – the manufacturing process is essentially the same but a premium blade will be better quality and should give a cleaner cut.  Please note that even though the sintering process will give a more durable blade, they can easily be damaged by incorrect usage (insufficient cooling, rock jams, etc).

For smaller blades, the sintered metal bond rim will be continuous around the whole rim while for larger blades (say above 16″ diameter), there may be sections cut out along the rim to improve coolant flow and debris removal – these are called Segmented Blades.

The 301 Gemking Blade made by Barranca/MK Diamond is often called a Notched Rim Blade but this is a bit misleading.  This one is still a sintered blade but the deep notches along the sintered metal bond rim allow for better coolant flow. This blade is designed for cutting of harder material but MUST be used with oil – water should not be used with these blades. This blade is just a slightly different type of sintered blade.

As the diamond particles are embedded in a metal rim, over time the surface of the metal bond can glaze over the diamond particles and affect cutting performance.  If you feel that the blade is not cutting as it should, we recommend “dressing” the blade by cutting into it a few times with an abrasive material (ie. dressing stick, old silicon carbide wheel, house brick, etc).  This process re-exposes the diamond particles allowing the blade to cut properly again.

B) Notched Rim

A classic notched rim diamond blade is made by pressing diamond grit into the edge of a solid steel core – the process leaves small notches along the rim where the diamond works to cut the material.  This is a much cheaper process compared to sintering and so these blades are generally much cheaper.  They will not last as long but are very low cost for those on a budget.

They can be made very thin which can be useful for those cutting material where you want minimal wastage.  The notches can be very thin or slightly thicker as shown in the photo above but there will be less diamond to work with compared to a sintered blade so factor this in when considering a blade of this type.

Like the sintered blades, these ones can be dressed if they appear to be slowing down but do this only as needed as these blades are nowhere near as durable as a sintered blade.

C) Electroplated 

Electroplated blades are made by electroplating a thin layer of diamond usually in a nickel metal bond on to the surface of the steel blade. As the diamond is only adhered in a very thin layer onto the surface of the blade rim, these blades are not as durable as a sintered blade.  They are generally quite a bit cheaper than a sintered blade but will not last as long – we do feel that they are better quality than the very cheap pressed Notched Rim blades though.

One advantage is that they can be made very thin so may suit applications where you want minimal wastage of valuable material.  They have also proved popular with our glass customers as a blade that cuts clean with less chipping. Generally not available in very large diameter blades and not suitable for slab saw applications.

These blades should NOT be dressed – this will just wear them out with no benefit. Make sure you are using plenty of coolant – the diamond will rip off in seconds if these blades are used dry or with insufficient coolant.

These are the three most commonly available lapidary saw blades – there are a few other less common types suitable for specialised applications (eg. CBN blades for cutting meteorites or iron-rich material).  Please consider your usage and available budget when selecting a diamond blade.  

The three most important specifications are blade diameter, blade thickness and bore size (ie. centre hole) – please note that these measurements are usually quoted in imperial measurements (inches).  See here for a quick conversion chart for relevant Metric/Imperial measurements.

If we can assist with any advice, please  us via the Contact Page.

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The Ultimate Guide to Diamond Saw Blades: Selecting the Ideal Blade for Your Project

Whether you’re a professional in the construction industry or a DIY enthusiast, choosing the appropriate diamond saw blade is crucial for the success of your concrete cutting projects. This guide aims to simplify the selection process, ensuring you make informed decisions for optimal results.

Why Opt for diamond saw blades?

Diamond saw blades stand out for their ability to cut through tough materials like concrete, stone, asphalt, and brick. They are embedded with industrial-grade diamonds, the hardest natural substance, which act as cutting teeth to easily grind through challenging materials.

Understanding the Components of Diamond Blades

Bond: This metal matrix holds the diamonds in place. A softer bond wears down quicker, exposing new diamonds for continuous cutting, while a harder bond offers more durability but may become less effective over time.

Diamond Concentration: Refers to the amount of diamonds in the blade’s cutting segment. Higher concentration means more diamonds in contact with the material, leading to faster cutting.

Segment Type: Segmented blades are best for dry cutting, whereas continuous rim blades are ideal for wet cutting and provide a smoother finish.

Gullets: Spaces between segments help in cooling and debris removal.

Selecting the Right Blade for Your Project

Material: Match the blade’s bond hardness to the material’s hardness.

Soft Materials (e.g., Asphalt, Green Concrete): Use a blade with a hard bond.

Medium Materials (e.g., Cured Concrete, Brick): A medium bond blade is suitable.

Hard Materials (e.g., Granite, Reinforced Concrete): A soft bond blade is recommended.

Cutting Type: Choose between wet or dry cutting.

Dry Cutting: Segmented blades provide necessary airflow and debris removal.

Wet Cutting: Continuous rim blades deliver a cleaner cut and reduce dust.

XMF contains other products and information you need, so please check it out.

Blade Size: Ensure the blade’s diameter is compatible with your saw. Larger blades allow for deeper cuts.

Additional Tips for Success

Invest in Quality: Opt for high-quality blades for enhanced durability and performance. Explore the range at Tyrolit Handsaw Blades.

Follow Proper Techniques: Adhere to the manufacturer’s guidelines and use appropriate safety gear.

Regular Inspection: Check your blade for signs of wear before each use.

Conclusion

Selecting the right diamond saw blade is essential for efficient and precise concrete cutting. By considering factors like material hardness, cutting type, and blade size, you can enhance your cutting experience and prolong the life of your tools.

Share your experiences or materials you typically cut in the comments below, and we’ll provide further tailored blade recommendations!

5 Steps To Select The Right Diamond Blade

Cut further, faster by selecting the right diamond blade for your cutting application. The best way to stay efficient on your job site is by minimizing downtime. If you have to stop and change your diamond blade every few cuts, you lose a lot of valuable time. Selecting the right diamond blade is crucial for several reasons, and it can significantly impact the efficiency, cost-effectiveness, and overall success of the project. Taking the time to understand the specific requirements of your project and choosing the appropriate diamond blade can make a significant difference in overall project success.

1. What Material Are You Cutting?

Diamond blades are made with different levels of bonded segments, ranging from soft to hard. To get the most out of your diamond blade, the segment and blade should be matched to the material it will cut. Being able to identify the type of material to be cut and the aggregate of the material can extend the life of your diamond blade drastically.

If you are cutting hard material like granite, stone, or brick, you want a softer-bonded blade like our Ol' Blue Blade. If you are cutting softer material like asphalt or concrete, you want a harder-bonded blade like our Boss Blade

2. What Equipment Are You Using?

Understand that the horsepower you are cutting with impacts the productivity and longevity of your diamond blade. The size of the blade should match the saw’s maximum horsepower. Cutting with a saw that runs too fast can cause the diamond blade to glaze over and get too hot. Cutting with a saw that runs too slow greatly affects the productivity and effectiveness of your diamond blade.

3. What is Your Depth of Cut?

Knowing how deep you need to cut before selecting your diamond blade allows for a more precise and accurate cut. The maximum cutting depth of a blade depends on the saw type and the saw’s components. Blade guards and motor housings can decrease the maximum depth of cut you can make with a blade. Check out our Diamond Blade Cutting Depths Gude for an overview of your maximum depth of cut based on saw type and blade diameter.

4. Are You Wet Cutting?

Knowing whether you need to use water with your diamond blade is important when selecting a blade. Any blades that are designed to cut wet MUST be used with water, while blades that are designed to cut dry can be used to cut both wet and dry.

Wet cutting is one of the most effective ways to cut concrete, masonry, stone, or even asphalt. Dust exposure is kept to a minimum and your diamond blade is less likely to overheat. The key is using the right amount of water. The slurry should almost have a chocolate milk consistency to it.

Phil White- Esch Construction Supply | Diamond Blade Expert

5. Can I Get More Longevity From This Blade?

A diamond blade's life depends on many different variables. One key factor of a diamond blade's life is the quality of the diamond blade. Diamond blades have different concentrations and quality of diamonds within the segments. A blade with a higher concentration and quality of diamonds will perform better and last longer.

Another factor is the blade specs. Make sure that your blade's segments are designed for the aggregate you are cutting. Cutting a hard material like old concrete will need a softer bonded segment on the blade than one used when cutting a more abrasive material like asphalt. A harder material requires more diamonds to be exposed in the segment. Soft bonded segments allow the diamonds to rise to the top to be exposed and grind away the material quickly. You could use a blade designed for hard material for asphalt, it will cut fast, but the diamond blade won't last long. 

The type of saw that is being used also makes a difference in the life of your blade. A saw with a higher RPM will wear a blade faster than a saw with a low RPM.

The saw operator plays a big role in the longevity of the blade. Applying too much pressure on the blade tends to wear the segments down faster than someone applying minimal pressure. 

Final Tips For Diamond Blade Production

1) Use a wet blade only when wet cutting

2) Don't bury the blade, let the saw cut by itself.

3) Make sure the blade is installed correctly

How to Select the Right Diamond Blade for Your Cutting Needs

When it comes to cutting through tough materials like concrete, asphalt, or stone, a high-quality diamond blade is your best friend. Diamond blades are engineered to offer precision, durability, and efficiency in a variety of cutting tasks. However, selecting the right diamond blade for your specific needs can be a daunting task with the multitude of options available. In this guide, we will help you navigate the key factors to consider when choosing the perfect diamond blade for your project.

Material Type

The first and foremost consideration when selecting a diamond blade is the material you intend to cut. Different materials have different hardness levels, and using the wrong blade can lead to inefficient cutting or even damage to the blade. Here are some common material categories and the types of blades suited for each:

a. Concrete: For cutting concrete, a diamond blade with a soft bond is ideal. Look for a segmented blade with a diamond concentration suitable for the concrete's hardness.

b. Asphalt: Asphalt blades are designed with undercut protection, and they come with a hard bond to withstand the abrasive nature of asphalt.

c. Stone: When cutting natural or engineered stone, choose a diamond blade with a continuous rim. The continuous rim design provides a clean and chip-free cut.

d. Masonry: Masonry blades are versatile and can cut through a range of materials, including bricks, blocks, and pavers. Opt for a segmented or turbo rim blade for masonry tasks.

Blade Diameter

The blade diameter is another crucial factor to consider. It determines the depth of your cuts. Ensure that the blade you choose has a diameter that matches the depth of your cuts. Using a blade with a smaller diameter may not allow you to achieve the desired cutting depth, while a larger blade might be inefficient and cause unnecessary wear.

Blade Type

Diamond blades come in various types, each designed for specific cutting applications. Here are some common blade types:

a. Segmented Blades: These blades have gullets (slots) that help with cooling and debris removal. They are suitable for cutting through hard materials like concrete and masonry.

b. Continuous Rim Blades: These blades are ideal for materials like tile, ceramic, and glass because they provide a clean, chip-free cut.

c. Turbo Blades: Turbo blades feature a serrated rim that combines the benefits of segmented and continuous rim blades. They are versatile and work well for a variety of materials.

d. Sintered Blades: Sintered blades are designed for cutting through extremely hard materials like granite and porcelain. They have a long lifespan but may be more expensive.

Wet vs. Dry Cutting

Consider whether your cutting task requires wet or dry cutting. Wet cutting involves using water to cool and lubricate the blade, reducing dust and increasing the blade's lifespan. Dry cutting is suitable for quick, small jobs but may create more dust and wear out the blade faster. Choose a blade that matches your cutting method.

Horsepower and RPM

Ensure that your saw or cutting equipment has the appropriate horsepower and RPM (revolutions per minute) rating to match the blade's requirements. Running a blade on equipment that doesn't meet its specifications can lead to inefficient cutting and premature wear.

Selecting the right diamond blade is essential to ensure the success of your cutting project. By considering factors such as the material type, blade diameter, type, wet or dry cutting, and equipment compatibility, you can make an informed decision and achieve precise, efficient cuts. Remember that investing in a high-quality diamond blade is an investment in the success and longevity of your project. So, before you start your next cutting task, take the time to choose the right diamond blade for the job. Your project's success depends on it!

If you are looking for more details, kindly visit Sintered General Purpose Blade(ar,pl,de).