Hi Derek,
I had a similar thing this trip with the same top screws of the blinds the rear kitchen blind, I used a slightly larger diameter screw of the same length and was able to tighten it up, I think what you may be experiencing is the point where the new self tapper has reached the maximum diameter of the existing hole and will need a bit more torque to cut its way into the steel frame enlarging the hole.
Btw, don't you just hate Phillips/Posidrive screws, so much better if we could get them in either hex or torx, no more slipping then! Perhaps someone knows of a supplier?
Chris