Aragorn was disguised. Yes, as simple as that.
Quote:
Tale of Years
2957-80 Aragorn undertakes his great journeys and errantries. As Thorongil he serves in disguise both Thengel of Rohan and Ecthelion II of Gondor.
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and, though Theoden did not recognize him, that is not because he haven't seen him before:
Quote:
LoTR, Book III, Chapter II
'I do not think your law was made for such a chance,' said Aragorn. 'Nor indeed am I a stranger; for I have been in this land before, more than once, and ridden with the host of the Rohirrim, though under other name and in other guise. You I have not seen before, for you are young, but I have spoken with Éomund your father, and with Théoden son of Thengel.
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