I had to cut a thin slit part way along an aluminum tube, roughly 1/8" thick. I tried cutting a shallow slot along the length of the tube, going 10 mils deeper with each pass. I started with a 10 mil thick blade I had, which had very fine teeth. I tried to go slow, but it jammed up when I got to the end where it was cutting quite a bit of material at once & it snapped in 2.01 pieces. The 0.01 piece turned out to be a tooth that got stuck in the slot. I went up to a 14 mil thick saw blade, which worked OK until I hit the 10 mil tooth. That blade shattered, and I still haven't found all the pieces. Fortunately, I was wearing safety glasses.
I finally cleaned out the slot & finished the job with a 20 mil blade. I also changed to cutting all the way through the wall at one end, and then advancing down the length to keep the amount of material being cut fairly constant.
I have a very mixed collection of slitting saw blades in various diameters, thicknesses & pitches. Are there any special guidelines on working with thin saws? I suspect the tooth pitch on the first blade may have been too fine. Are the feeds & speeds the same as for regular work? There is no apparent "set" on the teeth, so it's hard to get the chips out.