These "X-order-allocation" failures are just an indication that you
are running out or memory. raid1 is explicitly written to cope.
If memory allocation fails it waits for some to be free, and it has
made sure in advance that there is some memory that it will get
first-dibs on when it becomes free, so there is no risk of deadlock.
However this does not explain why you are getting unkillable
processes.
Can you try to put swap on just one of the partitions that your raid1
together instead of on the raid1 array and see if you can get
processes to become unkillable.
Also, can you find out what that process is doing when it is
unkillable.
If you compile with alt-sysrq support, then alt-sysrq-t should print
the process table. If you can get this out of dmesg and run if though
ksymoops it might be most interesting.
NeilBrown
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