I can sympathize with your problems. I have an answer that works well for me I will give you all the parameters that work with my 211. Of course run on 240/220 volts using straight argon 030 wire 4043. wire speed all the way up to 90 or 100 depending on your taste. Use the setting of 3/8s metal that throws the little 211 into a spray mode of sorts hold nozzle about 1inch away from parent metal to keep from frying tips and it does fine on 3/16s aluminum for me. I hope this helps, I am a retired boilermaker of 40 years, I fought it for a little bit but this works well for me hope it will for you .