I've had barrels, usually cheaper ones, where the gas port on the barrel is a bit forward of where it should be. For instance:
I had a 20" barrel that had a gas port like this. I installed an adjustable gas block on it set tight against the shoulder. No matter what I did, even with the adjustable gas block fully open it would short cycle and not pick up the next round. I measured and the gas port was a little further forward toward the muzzle than normal. So I had to move the adjustable gas block forward to match the gas ports together to get it to cycle. It didn't take much, maybe 1mm or so. I never had another problem with it after that, cycled everything and the gas adjustment actually worked as designed.
Not sure what doesn't make sense? Not trying to reinvent anything. Not all barrels are equal. Differences in the distance in gas port to barrel shoulder, differences in gas port diameter, chamfer on top of the gas port can all make a rifle not cycle properly if the gas port in the barrel isn't aligned properly with the port in the gas block. Not to mention differences in the measurements in gas blocks.
So my point was: If the gas ports between the barrel and gas block don't match up properly, you may have to move the block to get them matched properly. The OP asked about Aero barrels, I have one right now on my desk in front of me that has a gas port drilled about 0.5mm forward where it normally is. You can butt an adjustable block up against the shoulder and open it all the way up but it's never going to cycle.