I'm sorry to hear you're having such trouble with these tips. I'm an industrial welder at Frazier Industrial Co. I weld everything from the shelves at Home Depot to the frames that were at the last World Trade Center. I weld with these tips 8-10 hours a day 5 days a week at voltages over 30 volts and have never had a problem with them melting or as you describe. All I can say is you may have gotten a bad batch because I've been using them for years. Actually I only saw/replied to your post because I ordered more, if you are welding aluminum these tips are not for you. You don't even have to use mig, it's more like Tig.