You bought him a business-class ticket? If there was no business availability on AS from SFO-ORD, AA's system will price that segment in economy and the rest in business. If business availability opens up, you can call in and switch him to business at no cost (an Expert Flyer subscription is useful here because you can set an alert).

Qatar Airways is using the Air France lounge in O'Hare. I've been there flying Finnair; it's nothing special.