What Hand Saw Is Used for Cutting Metal? The Hacksaw Explained
The hand saw used for cutting metal is called a hacksaw. It has a thin, fine-toothed steel blade held under tension in a C-shaped or D-shaped frame, and it cuts on the push stroke. Choose the blade by the thickness and type of metal you are cutting, and you can handle pipe, bar, bolts, and sheet by hand.
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Mossy Oak MO17009The short answer: a hacksaw
A hacksaw is the standard hand saw for metal. Unlike a wood saw, its blade is narrow, hard, and covered in very small teeth that shave away tiny chips of steel, aluminum, copper, or brass.
Most hacksaws use a replaceable blade stretched tight between two pins on a frame. The tension keeps the blade straight so the cut stays on your line. You will also see this tool called a metal-cutting hand saw, a frame saw for metal, or just a hack saw. They all mean the same thing.
If you are weighing the hacksaw against power options, our best metal cutting tool page compares the main ways to cut metal. For hand models specifically, see our best hand saw for cutting metal comparison.
How a hacksaw cuts metal
Metal needs many small teeth in contact with the work at once. A hacksaw blade is built for that. At least two or three teeth should touch the material at all times, which keeps the blade from snagging or stripping teeth.
The teeth point away from the handle, so the blade cuts on the forward stroke. On the return stroke, ease off the pressure and let the blade glide back. Pressing down on the backstroke only dulls the teeth faster.
Blades are also set, meaning the teeth are bent slightly side to side. This makes the cut slightly wider than the blade so it does not bind in the groove.
Choosing the right blade
The blade matters more than the frame. Two things decide most of your choice: the tooth count, listed as TPI (teeth per inch), and the blade material.
Thick metal calls for fewer, larger teeth. Thin metal calls for more, smaller teeth. Bi-metal blades pair a flexible spine with hard cutting teeth, which makes them a common choice for general metalwork. Plain carbon blades wear faster on hard steel, and they can snap more easily.
| Material or shape | General TPI guidance | Why |
|---|---|---|
| Thick bar, soft metals such as aluminum or copper | 14 to 18 TPI | Larger teeth clear chips and resist clogging |
| Mild steel, angle iron, general work | 18 to 24 TPI | A good all-round balance |
| Thin tube, sheet, conduit | 24 to 32 TPI | Keeps several teeth on thin walls |
| Hardened steel or stainless | Fine teeth, bi-metal blade | Heat-resistant teeth hold up longer |
Other hand saws that can cut metal
The hacksaw is the main choice, but it is not the only one. A few other hand tools handle specific jobs.
Which one fits depends on the shape of the work and how clean the cut needs to be.
- Junior hacksaw: a small frame for tight spots and thin material.
- Jab or mini hacksaw: a handle that holds a short blade or a snapped-off piece of one, good for awkward angles.
- Tubing or pipe saw: a narrow blade for cutting pipe where a full frame will not fit.
- Jeweler's saw: a very fine frame saw for thin sheet and detail work in brass, copper, or silver.
- Coping or fret saw with a metal blade: for light curved cuts in soft sheet metal.
How to make a clean cut by hand
Good technique saves blades and makes the cut straighter. Follow these steps for most jobs.
- Clamp the work firmly in a vise, with the cut line close to the jaws to reduce vibration.
- Mark the line with a scribe or marker, and file a small notch to start the blade.
- Install the blade with the teeth facing forward, away from the handle, and tighten until it is taut.
- Start with light, steady strokes, using the full length of the blade.
- Push forward with pressure and lift slightly on the return.
- Slow down near the end of the cut and support the offcut so it does not fall or tear.
- File off burrs and sharp edges once you are through.
When to move to a power saw
A hacksaw is slow on thick stock or on many repeated cuts. If you are cutting a lot of metal, a power tool saves time and effort.
An angle grinder with a cutting disc is fast for rough work, and our best angle grinder disc for cutting metal page covers the disc options. For straight, repeatable cuts in bar and tube, a band saw is a better fit. See best band saw for metal for the machines and best band saw blades for metal for blade choices.
For a few occasional cuts on pipe, bolts, or small bar, a good hacksaw is usually enough.
Safety notes
Cut metal is sharp and often hot. Wear safety glasses to protect your eyes from flying chips and a snapped blade, and wear gloves when handling freshly cut pieces. Blades can break under strain, so keep your free hand clear of the line of the cut.
Always clamp the work. Holding metal by hand while sawing is a common cause of cuts and slips. If you switch to a power tool, add hearing protection, and make sure cords and guards are in good condition before you start.
Frequently asked questions
Can I use a wood saw to cut metal?
No. Wood saw teeth are too large and too soft, and they will dull or chip quickly on metal. Use a hacksaw blade made for the material.
Should the hacksaw blade teeth face toward or away from me?
Away from you, pointing toward the front of the frame. The saw cuts on the push stroke.
Why does my hacksaw blade keep breaking?
Common causes are a loose blade, too much pressure, twisting the saw mid-cut, or a tooth count that is too coarse for thin metal.
Do I need to oil the blade?
A drop of cutting oil helps when sawing steel because it reduces heat and wear. Aluminum and softer metals often cut fine with a little lubricant too.
What does bi-metal mean on a blade?
It means the blade combines two steels: a tough, flexible body and hardened cutting teeth. This helps the blade last longer and resist snapping.