Fix stall-clock refresh on duplicates and overflow suppression in fragment resync

Two fixes to stalledBroadcastFragmentIDs bookkeeping in
BLEFragmentAssemblyBuffer:

- Duplicate fragments no longer reset the stall clock. Fragment packets
  bypass the packet deduplicator, so relayed duplicates of an
  already-held index arriving every few seconds kept lastFragmentAt
  fresh and suppressed the targeted REQUEST_SYNC indefinitely. Now
  lastFragmentAt only updates when the index is new (actual progress).

- Only the streams that will actually be encoded on the wire are
  rate-limited. Previously every stalled candidate got
  lastResyncRequestAt set, but encodeFragmentIdFilter serializes at most
  RequestSyncPacket.maxFragmentIdFilterCount (60) IDs, so overflow
  streams were suppressed for retryAfter without ever being requested.
  Selection now caps at that shared constant, oldest stall first, so
  overflow stays eligible and rotates fairly on the next pass.

Tests: duplicates arriving periodically still trigger the stall report;
70 stalled streams yield the 60 oldest on the first pass and the
remaining 10 on the next.

Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>

bitchat/Services/BLE/BLEFragmentAssemblyBuffer.swift

@@ -108,8 +108,15 @@ struct BLEFragmentAssemblyBuffer {
             return .oversized(header: header, projectedSize: projectedSize, limit: limit, started: started)
         }
 
+        // Only actual progress resets the stall clock: fragment packets
+        // bypass the packet deduplicator, so relayed duplicates of an
+        // already-held index must not keep suppressing the targeted
+        // REQUEST_SYNC for a stalled stream.
+        let isNewIndex = fragmentsByKey[header.key]?[header.index] == nil
         fragmentsByKey[header.key]?[header.index] = header.fragmentData
-        metadataByKey[header.key]?.lastFragmentAt = now
+        if isNewIndex {
+            metadataByKey[header.key]?.lastFragmentAt = now
+        }
 
         guard let fragments = fragmentsByKey[header.key],
               fragments.count == header.total else {
@@ -156,14 +163,18 @@ struct BLEFragmentAssemblyBuffer {
     /// reassemblies that have not seen a new fragment for `stalledAfter`
     /// seconds — candidates for a targeted REQUEST_SYNC. Each returned
     /// stream is marked so it is not re-requested within `retryAfter`.
-    /// Directed reassemblies are excluded: peers only archive broadcast
-    /// fragments for gossip sync, so a targeted request cannot recover them.
+    /// At most `RequestSyncPacket.maxFragmentIdFilterCount` streams are
+    /// returned per pass — the wire filter cannot carry more — selected
+    /// oldest-stall first; overflow streams stay unmarked and eligible for
+    /// the next pass. Directed reassemblies are excluded: peers only archive
+    /// broadcast fragments for gossip sync, so a targeted request cannot
+    /// recover them.
     mutating func stalledBroadcastFragmentIDs(
         stalledAfter: TimeInterval,
         retryAfter: TimeInterval,
         now: Date = Date()
     ) -> [Data] {
-        var stalled: [Data] = []
+        var candidates: [(key: BLEFragmentKey, lastFragmentAt: Date)] = []
         for (key, metadata) in metadataByKey {
             guard metadata.isBroadcast,
                   let fragments = fragmentsByKey[key],
@@ -171,10 +182,24 @@ struct BLEFragmentAssemblyBuffer {
                   now.timeIntervalSince(metadata.lastFragmentAt) >= stalledAfter else { continue }
             if let lastRequest = metadata.lastResyncRequestAt,
                now.timeIntervalSince(lastRequest) < retryAfter { continue }
-            metadataByKey[key]?.lastResyncRequestAt = now
-            stalled.append(withUnsafeBytes(of: key.id.bigEndian) { Data($0) })
+            candidates.append((key: key, lastFragmentAt: metadata.lastFragmentAt))
+        }
+
+        // Mark only the streams that will actually go on the wire, so the
+        // overflow is not silently suppressed for `retryAfter`.
+        let selected = candidates
+            .sorted {
+                if $0.lastFragmentAt != $1.lastFragmentAt {
+                    return $0.lastFragmentAt < $1.lastFragmentAt
+                }
+                return ($0.key.sender, $0.key.id) < ($1.key.sender, $1.key.id)
+            }
+            .prefix(RequestSyncPacket.maxFragmentIdFilterCount)
+
+        return selected.map { candidate in
+            metadataByKey[candidate.key]?.lastResyncRequestAt = now
+            return withUnsafeBytes(of: candidate.key.id.bigEndian) { Data($0) }
         }
-        return stalled
     }
 
     private static func assemblyLimit(for originalType: UInt8) -> Int {

bitchatTests/Services/BLEFragmentAssemblyBufferTests.swift

@@ -192,6 +192,64 @@ struct BLEFragmentAssemblyBufferTests {
         #expect(afterCompletion.isEmpty)
     }
 
+    @Test
+    func duplicateFragmentsDoNotResetStallClock() throws {
+        var buffer = BLEFragmentAssemblyBuffer()
+        let fragmentID = Data((20...27).map { UInt8($0) })
+        let packet = makePacket(payload: makePayload(count: 256))
+        let fragments = try makeFragments(for: packet, chunkSize: 128, fragmentID: fragmentID)
+        let first = try #require(BLEFragmentHeader(packet: fragments[0]))
+
+        let t0 = Date(timeIntervalSince1970: 100)
+        _ = buffer.append(first, maxInFlightAssemblies: 8, now: t0)
+
+        // Relay duplicates of the same index arrive every few seconds; they
+        // bring no new data, so they must not keep the stream "fresh".
+        _ = buffer.append(first, maxInFlightAssemblies: 8, now: t0.addingTimeInterval(3))
+        _ = buffer.append(first, maxInFlightAssemblies: 8, now: t0.addingTimeInterval(5))
+
+        let stalled = buffer.stalledBroadcastFragmentIDs(stalledAfter: 5, retryAfter: 10, now: t0.addingTimeInterval(6))
+        #expect(stalled == [fragmentID])
+    }
+
+    @Test
+    func overflowStalledStreamsRotateAcrossPasses() throws {
+        var buffer = BLEFragmentAssemblyBuffer()
+        let cap = RequestSyncPacket.maxFragmentIdFilterCount
+        let streamCount = cap + 10
+        let t0 = Date(timeIntervalSince1970: 100)
+
+        // Incomplete broadcast assemblies with staggered last-fragment times
+        // (stream 0 is the oldest stall).
+        var ids: [Data] = []
+        for i in 0..<streamCount {
+            let fragmentID = Data([0xAB, 0, 0, 0, 0, 0, UInt8(i >> 8), UInt8(i & 0xFF)])
+            ids.append(fragmentID)
+            let header = try #require(BLEFragmentHeader(packet: makeFragmentPacket(
+                fragmentID: fragmentID,
+                index: 0,
+                total: 2,
+                originalType: MessageType.message.rawValue,
+                fragmentData: Data([0x01])
+            )))
+            _ = buffer.append(header, maxInFlightAssemblies: streamCount, now: t0.addingTimeInterval(Double(i)))
+        }
+
+        // All streams are stalled; only the cap's worth (oldest first) is
+        // requested and rate-limited, the overflow stays eligible.
+        let firstPassAt = t0.addingTimeInterval(Double(streamCount) + 5)
+        let firstPass = buffer.stalledBroadcastFragmentIDs(stalledAfter: 5, retryAfter: 60, now: firstPassAt)
+        #expect(firstPass == Array(ids.prefix(cap)))
+
+        // Next pass picks up exactly the overflow streams.
+        let secondPass = buffer.stalledBroadcastFragmentIDs(stalledAfter: 5, retryAfter: 60, now: firstPassAt.addingTimeInterval(1))
+        #expect(secondPass == Array(ids.suffix(streamCount - cap)))
+
+        // Nothing left until a retry window lapses.
+        let thirdPass = buffer.stalledBroadcastFragmentIDs(stalledAfter: 5, retryAfter: 60, now: firstPassAt.addingTimeInterval(2))
+        #expect(thirdPass.isEmpty)
+    }
+
     @Test
     func directedAssembliesAreNeverReportedAsStalled() throws {
         var buffer = BLEFragmentAssemblyBuffer()