I'm fairly sure that distance plays a role too.
I did a primary fall this A.M. alone for about 25 minutes before anybody showed up to spell me.
I was so freaking tired of running. Obviously the aggression is way scaled down for smaller numbers of hunters at a fall. Since I was doing all the damage they were entirely focused on me til my back-up showed up.
Didn't even bring coffee....
Hmm TGreens post makes sense for the most part, but your post implies that threat is decided on each mob (unless I got the wrong end of the stick) which doesn't explain why in an arkfall with say 6 total players (inc me) the Monarch spawns and will run through all five other players to get to me mostly the first I know about the monarch is when it tries to eat me, I have dealt it no damage and was the furthest player from it... not really a problem with the monarch as they are easy to keep out of the way of but when 5 Hellbugs keep shooting up from out of the ground knocking me flying repeatedly and all I've been doing is targeting Archers it gets a little frustrating, another example is the Blue Crystal Hellbug Arkfalls (Sure there's a proper name) when a ring of blast pods appears they all seem to target one person and you just better hope its not you, solution is to keep moving but I must say it's amusing to see the piles of bodies formed from ppl trying to revive someone before the pods are destroyed.
Scripted events that eg. occur periodically where all threat towards the mob becomes reduced either by or to (eg. 0) a certain amount and subsequently switches aggro and starts attacking another player (or the same if the original target builds threat back up quickly).
For the example of the Hellion I suspect that the Boss has an threat dump that coincides with each 1 or 2 spits. He can still hit the same target multiple times if it continues to deal damage.