[jbman45]

As we all know aluminum is supposed to have a balled tungsten. The ole classic way was to reverse polarity and strike an arc against brass which gives you a EP arc which balls the tungsten and brass won't contaminate it. Also there is a chemical sharpening tool you can use which balls nicely but don't know the cost, probably high.

I couldn't find a way to reverse polarity to ball tungsten for aluminum on the 200P since it's hard wired in....but eventually figured out a neat trick. Strike an arc on a brass object with a nicely tapered tungsten, then start to increase your cleaning knob setting. as you approach 50% then 60 or so you will see you're actually going to EP mode and the electrode begins to ball. Don't go too far and you'll have a nice ball for aluminum work. Go too far and you'll consume too much electrode. But use some form of copper to keep the contaminants down.

PS: Don't tell those miller guys....