I had a debate with a now former member a year or so ago about this same subject.
When I worked for Kirby, I was told that the plastic model being eleven blade and aerodynamicly designed moved more air than the 10 blade aluminum, however, the former member had data that suggested the aluminum fan with deeper fins moved the greater amount of CFM.
Your observations are the same as mine, the aluminum fan give the Kirby a more low pitched growl, where as the plastic fan is higher pitched, presumed from the higher motor revs.
I was told, and have no data to support the heresay, but was told that the plastic fan was better balanced and easier on the motor in high speed operation. Again I have no proof.