First, Silver CSRs are not reconciled. They are based on your estimated AGI. So if you estimate 249% of FPL for your AGI, then you will get Silver CSR73 even if your AGI ends up being 251% of FPL on your tax return.
The ACA subsidies (APTC) are reconciled on your tax return on Form 8962. I think the proper way to look at this is as a parallel tax system. The marginal rates are higher (sometimes much higher) than indicated by the Applicable Percentage in the 8962 instructions. See here to understand why:
https://seattlecyclone.com/aca-premium-tax-credits-2021-edition/I tend to favor Roth conversions over traditional IRA distributions. Taxwise it's the same thing, but if you end up not spending some of it, what is unspent ends up in a tax-free Roth rather than a taxable account.
As for your actual three questions:
A1. I would do Roth conversions up to where the marginal tax rate on the last dollar is about the same or a bit less than your estimated marginal tax rate when you're in your late 70s. Your late 70s rate will be based on RMDs, SS, other income, tax rates then, and IRMAA, so it's a bit of a guess, but you can at least make an estimate. This may be only $15K; it may be more or less depending on what you learn about your ACA marginal rate (see above).
A2. Probably his, simply because he's older and will hit RMDs first. But if either of you had a small IRA and wanted to simplify by emptying out that account, there can be value in that. This assumes no concerns about divorce or blended families where what you have individually might matter more than the old fashioned "all in one pot" approach.
A3. Each conversion has it's own 5 year clock which starts on January 1st of the year in which the conversion was made, regardless of when during the year it was made. So a Roth conversion today would have a five year clock starting on 1/1/2023 and being accessible on 1/1/2028.
As an aside, don't forget to report your Roth conversions on Form 8606 part II. If you do his and hers conversions, then you will complete two Form 8606s, one for each person. Submit the Form 8606(s) with your tax return.
HTH.