First of all, make sure your machine is capable of welding aluminum. Must be AC, high frequency capable with some sort of remote amperage control--such as a foot pedal.
Second, make sure your tig torch is hooked up electrode negative. Otherwise, your tungsten will just melt away as you describe.
Third, stay within the amperage limits of the diameter tungsten you are using. The higher the amperage, the thicker the tungsten. For most general purpose welding, a 3/32 tungsten will be fine.
Forth, make sure you have adequate argon gas shielding. 15-20 cfh should be plenty.
Finally, use the proper tungsten for the work. This also depends on the machine you're using. For decades, pure tungsten has been recommended for welding aluminum. This is not the case with the invert machines. I recommend using 2% lanthanated tungsten for everything. That way you don't have to stock various types of electrodes depending on what you are welding on. The 2% lanth works for AC and DC, no problem.
Good luck.
Depends on the thickness and quality of the aluminum.
Are you sure the GAS is on?
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