Hi there,
did you mean that your using a thoriated tungsten electrode sharpened to a 'bluntish'point?
In my training through my apprenticeship & from other tradesman I have always been told for aluminium to use a zirconiated tungsten(aluminium only),apparently mildly radioactive,so you can use ceriated or lanthiated as alternatives(both can be used for for mild steel,stainless steel,or aluminium)And then for aluminium use it broken off square/clean or balled up(increase amps or use DC+ to ball up)Try to direct your ark evenly between both sections being joined.I find at the start sometimes it will only direct at one surface at a time,so I aim at one & then the other & quick as possible give a wipe with the filler rod between both of them,then the ark stabilizes.Better to start with amps too low and work up,rather than have it all drop away.The aluminium oxide coating melts at a higher temperature than the aluminium itself,so make sure its as clean as possible(grind/sand if necessary).If it is a bit old or dirty a few 'dabs' or 'wipes' with the filler rod can help get the molten pool started!
Good luck hope it works out for you!Aluminium is great fun to weld when you get the hang of it.
Adric Maggs
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