Is Illustrator going to add a document raster effects settings default option of 96dpi?
Probably not. But you can set that up in your own template file or New Document Profile.
Yes, I did that. If I export you would think it would keep my same pixel artboard size at 96dpi, but it's not. A 640 wide @ 96 pixels document exported out of Illustrator, opens in Photoshop as 854 pixels wide @ 96dpi.
Document raster export settings have nothing to do with export resolution.
When you want to keep your pixel dimensions, you have to export at 72 ppi. That's hard-wired into Illustrator.
If you insist in exporting at 96 ppi, then you have to do the math first and set up your document in a size that gives you the desired pixel dimensions on export.
I suppose you are exporting for use on the web? resolution doesn't matter for the browser.
Exporting for use in email. I have both settings set up for 96, but Illustrator only likes exporting to it's default settings it seems. I can do the math as you suggest or continue to open in photoshop and adjust settings there. I appreciate your response. Thanks.
The document raster effects settings has nothing to do with export resolution, only with the resolution used to calculate raster effects like drop shadows. Changing the export resolution to anything higher than 72 ppi will create more pixels.
And what Monika said.