fix: extend env var expansion to CLI and gateway config loaders

The original PR (#2680) only wired _expand_env_vars into load_config(),
which is used by 'hermes tools' and 'hermes setup'. The two primary
config paths were missed:

- load_cli_config() in cli.py (interactive CLI)
- Module-level _cfg in gateway/run.py (gateway — bridges api_keys to env vars)

Also:
- Remove redundant 'import re' (already imported at module level)
- Add missing blank lines between top-level functions (PEP 8)
- Add tests for load_cli_config() expansion

cli.py

@@ -301,7 +301,11 @@ def load_cli_config() -> Dict[str, Any]:
                 defaults["agent"]["max_turns"] = file_config["max_turns"]
         except Exception as e:
             logger.warning("Failed to load cli-config.yaml: %s", e)
-    
+
+    # Expand ${ENV_VAR} references in config values before bridging to env vars.
+    from hermes_cli.config import _expand_env_vars
+    defaults = _expand_env_vars(defaults)
+
     # Apply terminal config to environment variables (so terminal_tool picks them up)
     terminal_config = defaults.get("terminal", {})
     

gateway/run.py

@@ -93,6 +93,9 @@ if _config_path.exists():
         import yaml as _yaml
         with open(_config_path, encoding="utf-8") as _f:
             _cfg = _yaml.safe_load(_f) or {}
+        # Expand ${ENV_VAR} references before bridging to env vars.
+        from hermes_cli.config import _expand_env_vars
+        _cfg = _expand_env_vars(_cfg)
         # Top-level simple values (fallback only — don't override .env)
         for _key, _val in _cfg.items():
             if isinstance(_val, (str, int, float, bool)) and _key not in os.environ:

hermes_cli/config.py

@@ -1179,7 +1179,6 @@ def _expand_env_vars(obj):
     None are left untouched.  Unresolved references (variable not in
     ``os.environ``) are kept verbatim so callers can detect them.
     """
-    import re
     if isinstance(obj, str):
         return re.sub(
             r"\${([^}]+)}",
@@ -1191,6 +1190,8 @@ def _expand_env_vars(obj):
     if isinstance(obj, list):
         return [_expand_env_vars(item) for item in obj]
     return obj
+
+
 def _normalize_max_turns_config(config: Dict[str, Any]) -> Dict[str, Any]:
     """Normalize legacy root-level max_turns into agent.max_turns."""
     config = dict(config)

tests/test_config_env_expansion.py

@@ -3,6 +3,7 @@
 import os
 import pytest
 from hermes_cli.config import _expand_env_vars, load_config
+from unittest.mock import patch as mock_patch
 
 
 class TestExpandEnvVars:
@@ -90,3 +91,42 @@ class TestLoadConfigExpansion:
         config = load_config()
 
         assert config["model"]["api_key"] == "${NOT_SET_XYZ_123}"
+
+
+class TestLoadCliConfigExpansion:
+    """Verify that load_cli_config() also expands ${VAR} references."""
+
+    def test_cli_config_expands_auxiliary_api_key(self, tmp_path, monkeypatch):
+        config_yaml = (
+            "auxiliary:\n"
+            "  vision:\n"
+            "    api_key: ${TEST_VISION_KEY_XYZ}\n"
+        )
+        config_file = tmp_path / "config.yaml"
+        config_file.write_text(config_yaml)
+
+        monkeypatch.setenv("TEST_VISION_KEY_XYZ", "vis-key-123")
+        # Patch the hermes home so load_cli_config finds our test config
+        monkeypatch.setattr("cli._hermes_home", tmp_path)
+
+        from cli import load_cli_config
+        config = load_cli_config()
+
+        assert config["auxiliary"]["vision"]["api_key"] == "vis-key-123"
+
+    def test_cli_config_unresolved_kept_verbatim(self, tmp_path, monkeypatch):
+        config_yaml = (
+            "auxiliary:\n"
+            "  vision:\n"
+            "    api_key: ${UNSET_CLI_VAR_ABC}\n"
+        )
+        config_file = tmp_path / "config.yaml"
+        config_file.write_text(config_yaml)
+
+        monkeypatch.delenv("UNSET_CLI_VAR_ABC", raising=False)
+        monkeypatch.setattr("cli._hermes_home", tmp_path)
+
+        from cli import load_cli_config
+        config = load_cli_config()
+
+        assert config["auxiliary"]["vision"]["api_key"] == "${UNSET_CLI_VAR_ABC}"