I wouldn't put any significance to the fact that Nightbloods physical form doesn't move when it's cognitive form does in the CR. You can go into the CR, find the bead of a sword laying forgotten in storage, carry the bead all over Shadesmar, manifest it, and the physical sword won't be affected at all.
Also, the aluminum sheath might not have a separate bead because he now sees the sheath as part of himself, so even if it wasn't part of his original construction it's now integrated into his Identity.
Now, I think Nightblood is going through alot of changes in WaT. Talking to honorblades to learn new abilities? Developing what seems to be more of a conscience and becoming more self-deterministic? My gut reaction while reading was that his consciousness was expanded after consuming the power of a Shard. Or at least what was probably an insignificant amount of power compared to the Shard, but was a glut of investiture to Nightblood.