I don't really have an answer for how common it is, or what the super hygroscopic bit is.
I used to do FASW until i learned about FASA. When i do FASA, i never wash the fumarate crystals with water. There shouldn't really be fumaric acid contam, because its concentration drops due to reacting with the freebase to form the salt, and all of the fumaric acid was in solution even before that drop occurred. So the only way i see for fumaric contam to happen, is due to evaporation of residual FASA if not washing the precipitated fumarate with dry cold clean acetone enough.
--
I have done water/sodcarb conversions several times, and yes it is pretty normal for the freebase to form an oily layer on top. It may or may not harden on its own, what i used to do was place it in the freezer and take it out when the freebase was hard but the water wasn't frozen yet.
There is (at least)
one way to get crystals in the bottom in a water/sodcarb conversion, you probably read that. I've made it work once, and tried two more times but ended up with the layer on top. I'm not sure which are the crucial points that made it work that one time.
In my attempts, once the freebase did form a layer on top, it would not sink and produce crystals anymore. You could re-x in heptane for large beautiful crystals
