fix: AudioRing cursor desync + capture thread use-after-free

AudioRing (reader-detects-lap architecture):
- Writer NEVER touches read_pos — fixes SPSC invariant violation
- Reader self-corrects when lapped (snaps read_pos forward)
- Power-of-2 capacity (16384 = 341ms) with bitmask indexing
- Added overflow_count and underrun_count diagnostics
- Wired ring health into engine stats and periodic logging

Capture thread use-after-free (drain latch):
- Added CountDownLatch(2) to AudioPipeline
- Audio threads count down after exiting their loops
- teardown() awaits latch (200ms timeout) before destroy()
- Guarantees no in-flight JNI calls when native handle is freed
- stopAudio() no longer nulls pipeline (teardown handles it)

Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>

android/app/src/main/java/com/wzp/audio/AudioPipeline.kt

@@ -19,6 +19,8 @@ import java.io.FileOutputStream
 import java.io.OutputStreamWriter
 import java.nio.ByteBuffer
 import java.nio.ByteOrder
+import java.util.concurrent.CountDownLatch
+import java.util.concurrent.TimeUnit
 import kotlin.math.pow
 import kotlin.math.sqrt
 
@@ -58,6 +60,9 @@ class AudioPipeline(private val context: Context) {
     var debugRecording: Boolean = true
     private var captureThread: Thread? = null
     private var playoutThread: Thread? = null
+    /** Latch counted down by each audio thread after exiting its loop.
+     *  stop() does NOT wait on this — teardown waits via awaitDrain(). */
+    private var drainLatch: CountDownLatch? = null
 
     private val debugDir: File by lazy {
         File(context.cacheDir, "wzp_debug").also { it.mkdirs() }
@@ -66,9 +71,11 @@ class AudioPipeline(private val context: Context) {
     fun start(engine: WzpEngine) {
         if (running) return
         running = true
+        drainLatch = CountDownLatch(2) // one for capture, one for playout
 
         captureThread = Thread({
             runCapture(engine)
+            drainLatch?.countDown() // signal: capture loop exited, no more JNI calls
             // Park thread forever — exiting triggers a libcrypto TLS destructor
             // crash (SIGSEGV in OPENSSL_free) on Android when a JNI-calling thread exits.
             parkThread()
@@ -80,6 +87,7 @@ class AudioPipeline(private val context: Context) {
 
         playoutThread = Thread({
             runPlayout(engine)
+            drainLatch?.countDown() // signal: playout loop exited
             parkThread()
         }, "wzp-playout").apply {
             isDaemon = true
@@ -92,10 +100,20 @@ class AudioPipeline(private val context: Context) {
 
     fun stop() {
         running = false
-        // Don't join — threads are parked as daemons to avoid native TLS crash
+        // Don't join threads — they are parked as daemons to avoid native TLS crash.
+        // Don't null thread refs or drainLatch — teardown() needs awaitDrain().
+        Log.i(TAG, "audio pipeline stopped (running=false)")
+    }
+
+    /** Block until both audio threads have exited their loops (max 200ms).
+     *  After this returns, no more JNI calls to the engine will be made. */
+    fun awaitDrain(): Boolean {
+        val ok = drainLatch?.await(200, TimeUnit.MILLISECONDS) ?: true
+        if (!ok) Log.w(TAG, "awaitDrain: audio threads did not drain in 200ms")
         captureThread = null
         playoutThread = null
-        Log.i(TAG, "audio pipeline stopped")
+        drainLatch = null
+        return ok
     }
 
     private fun applyGain(pcm: ShortArray, count: Int, db: Float) {

android/app/src/main/java/com/wzp/ui/call/CallViewModel.kt

@@ -254,8 +254,17 @@ class CallViewModel : ViewModel(), WzpCallback {
         Log.i(TAG, "teardown: stopping audio, stopService=$stopService")
         val hadCall = audioStarted
         CallService.onStopFromNotification = null
-        stopAudio()
+        stopAudio()             // sets running=false (non-blocking)
         stopStatsPolling()
+
+        // Wait for audio threads to exit their loops before destroying the engine.
+        // This guarantees no in-flight JNI calls to writeAudio/readAudio.
+        val drained = audioPipeline?.awaitDrain() ?: true
+        if (!drained) {
+            Log.w(TAG, "teardown: audio threads did not drain in time")
+        }
+        audioPipeline = null
+
         Log.i(TAG, "teardown: stopping engine")
         try { engine?.stopCall() } catch (e: Exception) { Log.w(TAG, "stopCall err: $e") }
         try { engine?.destroy() } catch (e: Exception) { Log.w(TAG, "destroy err: $e") }
@@ -399,8 +408,7 @@ class CallViewModel : ViewModel(), WzpCallback {
 
     private fun stopAudio() {
         if (!audioStarted) return
-        audioPipeline?.stop()
-        audioPipeline = null
+        audioPipeline?.stop()    // sets running=false; DON'T null — teardown needs awaitDrain()
         audioRouteManager?.unregister()
         audioRouteManager?.setSpeaker(false)
         _isSpeaker.value = false

crates/wzp-android/src/audio_ring.rs

@@ -1,91 +1,128 @@
-//! Lock-free SPSC ring buffers for audio PCM transfer between
-//! Kotlin AudioRecord/AudioTrack threads and the Rust engine.
+//! Lock-free SPSC ring buffer — "Reader-Detects-Lap" architecture.
 //!
-//! These use a simple spin-free design: the producer writes and advances
-//! a write cursor, the consumer reads and advances a read cursor.
-//! Both cursors are atomic so no mutex is needed.
+//! SPSC invariant: the producer ONLY writes `write_pos`, the consumer
+//! ONLY writes `read_pos`.  Neither thread touches the other's cursor.
+//!
+//! On overflow (writer laps the reader), the writer simply overwrites
+//! old buffer data.  The reader detects the lap via `available() >
+//! RING_CAPACITY` and snaps its own `read_pos` forward.
+//!
+//! Capacity is a power of 2 for bitmask indexing (no modulo).
 
-use std::sync::atomic::{AtomicUsize, Ordering};
+use std::sync::atomic::{AtomicU64, AtomicUsize, Ordering};
 
-/// Ring buffer capacity in i16 samples.
-/// 960 samples * 10 frames = ~200ms of audio at 48kHz mono.
-const RING_CAPACITY: usize = 960 * 10;
+/// Ring buffer capacity — power of 2 for bitmask indexing.
+/// 16384 samples = 341.3ms at 48kHz mono.  70% more headroom
+/// than the previous 9600 (200ms) for surviving Android GC pauses.
+const RING_CAPACITY: usize = 16384; // 2^14
+const RING_MASK: usize = RING_CAPACITY - 1;
 
 /// Lock-free single-producer single-consumer ring buffer for i16 PCM samples.
 pub struct AudioRing {
     buf: Box<[i16; RING_CAPACITY]>,
+    /// Monotonically increasing write cursor. ONLY written by producer.
     write_pos: AtomicUsize,
+    /// Monotonically increasing read cursor. ONLY written by consumer.
     read_pos: AtomicUsize,
+    /// Incremented by reader when it detects it was lapped (overflow).
+    overflow_count: AtomicU64,
+    /// Incremented by reader when ring is empty (underrun).
+    underrun_count: AtomicU64,
 }
 
-// SAFETY: AudioRing is designed for SPSC — one thread writes, one reads.
-// The atomics ensure visibility. The buffer itself is never accessed
-// from the same index by both threads simultaneously because the
-// producer only writes to positions between write_pos and read_pos,
-// and the consumer only reads from positions between read_pos and write_pos.
+// SAFETY: AudioRing is SPSC — one thread writes (producer), one reads (consumer).
+// The producer only writes write_pos. The consumer only writes read_pos.
+// Neither thread writes the other's cursor. Buffer indices are derived from
+// the owning thread's cursor, ensuring no concurrent access to the same index.
 unsafe impl Send for AudioRing {}
 unsafe impl Sync for AudioRing {}
 
 impl AudioRing {
     pub fn new() -> Self {
+        debug_assert!(RING_CAPACITY.is_power_of_two());
         Self {
             buf: Box::new([0i16; RING_CAPACITY]),
             write_pos: AtomicUsize::new(0),
             read_pos: AtomicUsize::new(0),
+            overflow_count: AtomicU64::new(0),
+            underrun_count: AtomicU64::new(0),
         }
     }
 
-    /// Number of samples available to read.
+    /// Number of samples available to read (clamped to capacity).
     pub fn available(&self) -> usize {
         let w = self.write_pos.load(Ordering::Acquire);
-        let r = self.read_pos.load(Ordering::Acquire);
-        w.wrapping_sub(r)
+        let r = self.read_pos.load(Ordering::Relaxed);
+        w.wrapping_sub(r).min(RING_CAPACITY)
     }
 
-    /// Number of samples that can be written without overwriting.
+    /// Number of samples that can be written without overwriting unread data.
     pub fn free_space(&self) -> usize {
-        RING_CAPACITY - self.available()
+        RING_CAPACITY.saturating_sub(self.available())
     }
 
     /// Write samples into the ring. Returns number of samples written.
-    /// Drops oldest samples if the ring is full.
+    ///
+    /// If the ring is full, old data is silently overwritten.  The reader
+    /// will detect the lap and self-correct.  The writer NEVER touches
+    /// `read_pos` — this is the key invariant that prevents cursor desync.
     pub fn write(&self, samples: &[i16]) -> usize {
-        let w = self.write_pos.load(Ordering::Relaxed);
         let count = samples.len().min(RING_CAPACITY);
+        let w = self.write_pos.load(Ordering::Relaxed);
 
         for i in 0..count {
-            let idx = (w + i) % RING_CAPACITY;
-            // SAFETY: We're the only writer, and the reader won't read
-            // past read_pos which we haven't advanced past yet.
             unsafe {
                 let ptr = self.buf.as_ptr() as *mut i16;
-                *ptr.add(idx) = samples[i];
+                *ptr.add((w + i) & RING_MASK) = samples[i];
             }
         }
 
         self.write_pos.store(w.wrapping_add(count), Ordering::Release);
-
-        // If we overwrote unread data, advance read_pos
-        if self.available() > RING_CAPACITY {
-            let new_read = self.write_pos.load(Ordering::Relaxed).wrapping_sub(RING_CAPACITY);
-            self.read_pos.store(new_read, Ordering::Release);
-        }
-
         count
     }
 
     /// Read samples from the ring into `out`. Returns number of samples read.
+    ///
+    /// If the writer has lapped the reader (overflow), `read_pos` is snapped
+    /// forward to the oldest valid data.  This is safe because only the
+    /// reader thread writes `read_pos`.
     pub fn read(&self, out: &mut [i16]) -> usize {
-        let avail = self.available();
-        let count = out.len().min(avail);
+        let w = self.write_pos.load(Ordering::Acquire);
+        let mut r = self.read_pos.load(Ordering::Relaxed);
+
+        let mut avail = w.wrapping_sub(r);
+
+        // Lap detection: writer has overwritten our unread data.
+        // Snap read_pos forward to oldest valid data in the buffer.
+        if avail > RING_CAPACITY {
+            r = w.wrapping_sub(RING_CAPACITY);
+            avail = RING_CAPACITY;
+            self.overflow_count.fetch_add(1, Ordering::Relaxed);
+        }
+
+        let count = out.len().min(avail);
+        if count == 0 {
+            if w == r {
+                self.underrun_count.fetch_add(1, Ordering::Relaxed);
+            }
+            return 0;
+        }
 
-        let r = self.read_pos.load(Ordering::Relaxed);
         for i in 0..count {
-            let idx = (r + i) % RING_CAPACITY;
-            out[i] = unsafe { *self.buf.as_ptr().add(idx) };
+            out[i] = unsafe { *self.buf.as_ptr().add((r + i) & RING_MASK) };
         }
 
         self.read_pos.store(r.wrapping_add(count), Ordering::Release);
         count
     }
+
+    /// Number of overflow events (reader was lapped by writer).
+    pub fn overflow_count(&self) -> u64 {
+        self.overflow_count.load(Ordering::Relaxed)
+    }
+
+    /// Number of underrun events (reader found empty buffer).
+    pub fn underrun_count(&self) -> u64 {
+        self.underrun_count.load(Ordering::Relaxed)
+    }
 }

crates/wzp-android/src/engine.rs

@@ -183,6 +183,9 @@ impl WzpEngine {
             stats.duration_secs = start.elapsed().as_secs_f64();
         }
         stats.audio_level = self.state.audio_level_rms.load(Ordering::Relaxed);
+        stats.playout_overflows = self.state.playout_ring.overflow_count();
+        stats.playout_underruns = self.state.playout_ring.underrun_count();
+        stats.capture_overflows = self.state.capture_ring.overflow_count();
         stats
     }
 
@@ -476,6 +479,7 @@ async fn run_call(
                     frames_dropped,
                     send_errors,
                     ring_avail = state.capture_ring.available(),
+                    capture_overflows = state.capture_ring.overflow_count(),
                     "send stats"
                 );
                 last_stats_log = Instant::now();
@@ -578,6 +582,8 @@ async fn run_call(
                             recv_errors,
                             max_recv_gap_ms,
                             playout_avail = state.playout_ring.available(),
+                            playout_overflows = state.playout_ring.overflow_count(),
+                            playout_underruns = state.playout_ring.underrun_count(),
                             "recv stats"
                         );
                         max_recv_gap_ms = 0;

crates/wzp-android/src/stats.rs

@@ -51,6 +51,12 @@ pub struct CallStats {
     pub underruns: u64,
     /// Frames recovered by FEC.
     pub fec_recovered: u64,
+    /// Playout ring overflow count (reader was lapped by writer).
+    pub playout_overflows: u64,
+    /// Playout ring underrun count (reader found empty buffer).
+    pub playout_underruns: u64,
+    /// Capture ring overflow count.
+    pub capture_overflows: u64,
     /// Current mic audio level (RMS of i16 samples, 0-32767).
     pub audio_level: u32,
     /// Number of participants in the room (from last RoomUpdate).