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When you are tig welding an aluminum butt joint that requires 100% penetration, cleanliness of the aluminum is very important. especially the sheared edge.
This video demonstrates just how much difference the material prep makes. even just a little extra effort in making sure the material is clean in the weld area makes a very big difference when it comes to achieving full and smooth penetration.

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There is a thing on instagram called the # razorbladechallenge.
Mostly using box cutter blades which are a bit easier than single edge razor blades.
TIg welding box cutter blades can be very good practice because it makes you get used to focusing your eyes on a very small puddle, you have to get used to using a very small filler wire, and you also see how beneficial it is to use aluminum backing on thin metal.

Visit my Store https://weldmongerstore.com/ to see new products like the #8 furick cup used in this video.

A job for a customer involved tig welding some heat treated 4140 to 1/4" drive Snap On Sockets.
In a previous job I had, it was very common to modify tools by welding sockets to round stock, making offsets in box end wrenches, making long extensions using 17-4 stainless etc...
We always used hastelloy W filler rod and it always worked.

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here are some amazon links for things shown in the video
knipex mini bolt cutters http://amzn.to/2xjzgPE

lincoln viking 3350 with 4C auto dark helmet http://amzn.to/2z0ONpG

welding magnifier/cheater lens http://amzn.to/2fTld0F

Lincoln TIG 200 square wave tig welder http://amzn.to/2fRUtxt

Walter mill scale wheel http://amzn.to/2xjKt7R

Walter flap discs http://amzn.to/2fThErq
TIG welding some carbon steel using a Furick #12 Tig cup.
First, I cleaned all the mill scale off using a Walter Mill Scale disc and a flap disc.
Then I set the welder to 170 amps.
You can weld most anything with 170 amps if you are welding to make multipass welds.
I used 25 cfh of argon, a 3/32" (2.4mm) 2% lanth electrode, and 1/16" (1.6mm) ER70s-6 wire.

visit my store here https://weldmongerstore.com/ This video adds to the conversation of a previous video where I experimented using 90 amps and 50hz vs 250hz on .070" (1.8mm) wall aluminum. guess what? 50 hz penetrated and 250hz did not.
So here are 2 good examples of using different AC frequency settings to achieve different results.