Export to PDF - Headers inconsistent , sometimes italics

Petaluma should be fine, of course, but I would recommend you go through the Font Styles and Paragraph Styles dialogs to make sure that none of the font and paragraph styles are set to use bold, italic or bold italic weights for the font, since none of them exist for real. I recently made some changes such that using Petaluma as the default font (as set in Preferences) will prevent font and paragraph styles from using unavailable styles, but I haven’t yet had a chance to extend this to the Engrave > Music Fonts dialog, though I plan to do so.