Hello Brian, two things for consideration with the information you have supplied thus far. I am thinking you are referring to welding aluminum/magnesium possibly? First off what diameter of tungsten are you using and what thickness and amperage range are you welding on? You may need to increase the diameter of the tungsten providing you don't have other machine adjustments that need to be looked at. Next, go through your instruction manual and determine the proper way to adjust the arc balance control, it is likely that you are running with the balance too far to the cleaning side of the setting. Try moving this adjustment towards the penetration side little by little, you should notice an improvement in the condition that you have mentioned. Others will likely have suggestions to stay tuned. Enjoy your machine and best regards, Allan
My first guess (and probably your most likely problem):
Are you aware that on the Dynasty 200DX, the machine automatically switches the polarity of the Dinse connectors, when you switch processes between stick and TIG. Your ground should always be connected to the left side, and your torch (or stinger for SMAW) should be connected to the right side (the side where the gas comes out).
I say this, because I routinely use 1/16" tungstens (that's 1/3 smaller than what you're using) up to 135A DC (which is pretty much as far as you can push them), and still do not get balling, but if your polarity is reversed, you will have severe balling problems.
Are you using helium as your shielding gas? It runs much hotter than argon.
When you say 2%, that is 2% what? I ask, because zirconated tungsten is meant for AC aluminum use, and is supposed to ball.