Hi Scott,
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1st question is why do the edges look transparent on the patches.
The edges you see in the Animation:Master realtime viewer are there because Animation:Master displays the decals at a very low resolution. I guess it does this so your graphics card doesn't run out of texture memory too soon for models and projects with a lot of textures. For rendering, A:M of course uses the textures at full resolution.
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And second is I had already decaled the irises and after painting with all but the face mesh hidden I get duplicated irises in my pws.
I'm not sure what caused the duplicate irises. I've never seen this kind of behaviour before. Maybe you accidentally copy/pasted the irises group in A:M. That would then also duplicate the decals. Other than that, I don't see how something like this could occur.
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I hit the face mesh for decal in painter then select the auto tile decal then select projection paint then lock but it still processes irises when I accept the projection paint.
Are you sure the irises are not in the same group as the face mesh? If the irises are both in the face mesh group and the irises group, that might explain why they are still processed in projection paint when you lock the face mesh.
Could you maybe send me the model so I could have a look at what might be wrong?
Best regards,
Filip