Ummm... Both copper and aluminum can be fashioned into round or flat wire. To have this discussion, you need to determine what will be static and what will be variable among the two materials while making comparisons. Probably 99% of all TC Sounds drivers use aluminum coils, do you think they all suffer from poor sound quality? I think what you're trying to discuss is mass and compliance relationships, along with thermal power handling, and while there is a slight difference in cooling properties between copper and aluminum, you could use either one for both SQ and SPL.
And poly cones will be more forgiving than ANY other cone material with regards to a harsh signal. It's proven that poly cones gently smooth over sharp edges in soundwaves when you compare the input and output signals. The best reason not to use poly for large bass drivers is simply due to a lack of rigidity over long spans in the material. You could reinforce it, but that adds mass which may or may not be desirable.