[Spiffy Lab]

I have a 12" Milwaukee chop saw. Have been using a Diablo 12" 96 TPI blade. It's been cutting the 1" or so copper and aluminum bar ok, but today it binded up and I lost 4 teeth. Would a 100 TPI blade give a better, smoother, easier cut?

[520052]

96 TPI toothed blades are primarily for cutting thin material. If you are cutting 1" thick material a blade with less teeth will actually cut "easier".

[Spiffy Lab]

Probably 1" down to 3/8" round stock. Only saw the softer metal like aluminum, copper and brass.

[520052]

On a 12" blade 4 extra teeth is meaningless. With what you are cutting 96 TPI is probably too many teeth. I personally cut aluminum all day with thickness from 1/8" to 3/8" with 300mm ( 11.81") 80 TPI triple chip grind blade from General Saw. What you want is a dedicated non ferrous blade of about 72-84 TPI for the material your cutting. The finer tooth blades teeth clog and do not cut well when used to cut thicker material. Hence the bind you experienced.

[Spiffy Lab]

Good info. Thank you all.