Perhaps your machine has a fault in the AC waveform. A few questions and comments for you.ONDGAS wrote:....notice the ball on my tungsten pulls to one side and almost looks like there is a split in the end of it....
tungsten 1/8 blue, and do the same thing and notice it's just not pooling nice....two puddles are around 80-100 amps and 75% bal and the lower one is when I try to add filler, it's almost like the filler is absorbed under the pubble....I hate aluminium? I feel like you need ten years experience on each conceivable weld in each conceivable position
I. Confirming you have the Master TIG MLS? In reviewing the Kemppi manual, appears that when you select "more positive" on your machine you are actually adding more DCEP (increased cathodic etching, increased electron transfer to the tungsten and ionic bombardment to the workpiece). This protocol is the exact OPPOSITE on how Lincoln and Miller transformer/inverter-based machines are adjusted, if we are interpreting the manual correctly. On a Lincoln/Miller, increasing the " % " increases the level of DCEN and the heat into the workpiece. Figured you understand this, but noting the differences for context. Try welding with the waveform, frequency, and balance at factory settings. Note, images show annotated clips from the Master TIG MLS.
II. Confirming your work piece is 6061-T6 Aluminum? Thickness of material? On Lincoln/Miller inverter machines we prefer 2% La (BLUE) Tungsten for Aluminum/Magnesium and 2% Th (RED) for ferrous materials. DGP Tri-Mix WS2 (CREAM) for special applications. On Aluminum material 3.2mm (1/8in) and greater, we run an 1/8" electrode with a balled end. Aluminum under 3.2mm, we switch to 2.4mm (3/32") Tungsten and down to 1.5mm (1/16") Tungsten for even thinner Aluminums. Although the balled Tungsten profile is common on transformer rigs, we find the spherical end maintains arc consistency, helps focus the plasma jet, and combats split ends. We also use a standard blunt end and regular 2:1 sharpened point with equal results.
III. Learn to appreciate Aluminum. The material requires a different mindset. In material preparation/fitup and when welding. Uncertain with your existing level of hood time on Aluminum. We prefer to START off someone NEW to TIG on Aluminum. The perceived "violence of action", IOPO, forces a welder to learn how to develop the molten puddle, control heat input, and develop sound tactics (dip, move; dip, move, etc a la a metronome) during the weld out. Also, never be in a rush to finish a weld line. Slow things down. You're in control of the process, not the torch or the pedal. Once you improve your Aluminum abilities, switching to ferrous material is less challenging.
IV. Online training and focused practice. As you know, Jody C. has a virtual bank vault replete with excellent video content and commentary on how to approach Aluminum welding. Another outstanding online source is Arron at http://www.6061.com/imagegallery.htm. His one-time, unlimited access, $45 subscription for professional Aluminum TIG training is worth it's weight in Scandium. Note, have no existing professional relationship with http://www.6061.com and above comments are not a funded endorsement.
....it ran. Might as well try everything else first right? 
