Muzzle flash and the concussion is not caused by unburned powder.
It is caused by gasses igniting when they hit the air. The fireball forms about a foot or two in front of the muzzle.
Military powders add anti-flash to the mix to prevent it. Some commercial powders do not. Such a powder in a short barrel can produce what I call a "bark" that is very painful if your are not wearing protection.
If you want more velocity, you want the pressure curve to drop less quickly. The peak of the curve for a slow and a fast powder will be the same.
The slower powder will drop more slowly and give more velocity. It does not matter if some of the powder is blown out the muzzle.
Yes, a faster powder will burn 100%, but you would use less of it, to keep the peak pressure at the limit, and then the curve would drop faster.
Trust me, us old farts are familiar with shot barrels. One common thing that I think every generation has done (starting round 1900) is to take a barrel and test it in 2" increments.
Hatcher has a good write up of his test in his book.
And on the wall of Fulton's, at Bisley, is a plaque with some barrel bits and the bullet that came out of them. The shortest barrel was about 3". The tip of the chambered bullet would be visible at the muzzle. The base of the bullet is mushroomed from the unsupported pressure when the bullet exited. Peak pressure is reached very quickly. I don't know how quickly, but I am guessing within the first 4 inches.
The idea they 1680 would produce more velocity than 4895 is ludicrous. By all means experiment, but be very careful you don't make a 1680 pipe bomb looking for that velocity.
You may recall that Hornady, a few years ago, offered a "Magnum" version of 308 and a few other calibers. The 308 I tested delivered an honest 200 fps increase. Made the 308 into a good 3006.
As you know, a 308 case holds about 48 gr of powder.
Before they case was neck down, they inserted 54 gr of slow powder in the straight walled case. Then, the case was put in a supporting, to hold the case walls in place, and a ram came down and compressed the powder into a solid mass. Then the case was necked into a 308.
I still have some of that ammo. I should dig it out and see what it does in a 20" Hog Hunter.
Some info on barrel length and velocity.
I have lots of 1680 and 4895. I could run the test in 303 or 308, but have no way here at home to adjust to the same peak pressure. I recently sold my 308 that had a pressure strain gauge on it.