Angle Grinders — Reviews & Buying Guide

Angle grinder reviews for weld prep, beveling, and finishing. Disc sizes, motor types, speed control, and brand comparisons from DeWalt, Makita, Milwaukee, Metabo, and others.

An angle grinder is the second most-used tool in a welding shop after the welder itself. You use it before welding for surface prep, beveling, cutting, and fit-up. You use it after welding for grinding flush, blending, and finishing. A welder without a grinder is like a painter without sandpaper.

What Welders Use Grinders For

Weld prep — Removing mill scale, rust, paint, and coatings from the weld zone. A clean surface prevents porosity, inclusions, and adhesion problems. Grinding a bevel on plate edges for full-penetration groove welds.

Cut-off — Thin cut-off wheels (1/16" to 1/8") slice through bar stock, angle iron, and tube faster than a hacksaw and more portably than a chop saw. Not as clean as a bandsaw cut, but fast and flexible.

Weld finishing — Grinding welds flush for appearance or for a flat mating surface. Blending weld toes to reduce stress risers. Smoothing multi-pass welds between passes. Flap discs are the go-to for finishing because they cut and blend in one step.

Surface conditioning — Scotch-Brite style discs and wire wheels clean surfaces without removing significant base metal. Used for final prep before painting or for cleaning stainless without iron contamination.

Disc Types for Welding

Grinding discs (1/4" thick, Type 27) are for aggressive stock removal. Use them for grinding welds flush and heavy bevel work. They remove metal fast but leave a rough surface.

Flap discs combine cutting and finishing. Available from 40-grit (aggressive) to 120-grit (fine finish). A 60-grit flap disc is the most versatile single disc for weld grinding and blending.

Cut-off wheels (1/16" or thinner) are for cutting only. Never grind with a cut-off wheel since they’re not designed for side loads and can shatter.

Wire wheels and cups remove rust, paint, and scale without removing base metal. Use knotted wire for aggressive cleaning and crimped wire for lighter work.

Articles in This Section

Reviews of angle grinders by size, brand, and power source. Disc selection guides and grinding technique tips for common welding prep and finishing tasks.

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