also yes companions die in hardcoe mode. look it up...
It was obviously a glitch on your end though with him spawning into the final battle with you, maybe he died because the game realized he wasn't supposed to be there? I am playing on hardcoe mode and haven't played on any other mode so I wasn't aware that companions dying was specific to hardcoe mode I just figured that if they died then they died lol.
@OP:
I tried your idea and didn't notice any difference
@ unwinding:
What does that have to do with anything? Also I have the original PS3 and it seems to me like it is still supported (I get system updates, all patches, and their repair service will still repair my PS3), so you are wrong.