proc.killed only means Node sent a signal — the process can still be alive.
This caused premature pool slot release, allowing unbounded process spawning.
- ensureProcessExit: remove proc.killed from early-exit checks, only trust exitCode
- Fix 3 call-site guards that skipped cleanup for signaled-but-alive processes
- Add TOTAL_PROCESS_HARD_CAP=10 safety net in waitForSlot()
- After SIGKILL, wait up to 1s via exit event instead of blind 200ms sleep
- Reduce reaper interval from 5min to 1min, idle threshold from 2min to 1min
Closes#1226
Co-authored-by: Claude Opus 4.6 <noreply@anthropic.com>
Nir Alfasi
38d9ac7adb