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With a suitably wedged NFS process I believe you can get a process that is stuck in D even if you `kill -9` it.

You're right, signal delivery does not interrupt an atomic operation, so if a syscall takes unusually long time (like network filesystems sometimes cause), the process hasn't received its SIGKILL yet.

I don't remember ever seeing Linux create a Zombie(Z) when a process is KILLed while in the (D) state. It just stays alive, stuck in D state.

A zombie is a process which has terminated but has not been waited for by its parent.

SIGKILLing a process blocked in an uninterruptible system call does not create a zombie.