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I notice at school in my Tig class you need to make sure the area that is grounded is really clean. The area your welding should also be really clean by brushing, grinding, filing or sanding.
In the class we normally weld on steel tables that are also used in the Mig, Stick and Tig classes. I am using the Tig on aluminum plate and .065. The stick welding guys are learning to be boiler makers and they leave a mess on the table during the night class, so I need to grind the table before I start during the day.
Good luck on finding the issue.
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