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A 115-volt welder can handle aluminum up to an eighth of an inch thick (3 mm) with adequate preheating, and a 230-volt machine can weld aluminum that's up to a quarter of an inch thick (6 mm). Consider a machine with an output greater than 200 amps if you will be welding aluminum daily.
The only type of electrode stocked in the tool room at that time was 2% thoriated electrodes and that is what we used on everything. Stainless, Nickel alloys, titanium, aluminum, magnesium ...all was welded using 2% thoriated tungsten. There were a few welders who managed to get some pure tungsten, or zirconiated tungsten for aluminum and magnesium but for the most part, even magnesium gearboxes were welded using 2% thoriated.