materializer + replay ports + vectord substrate fix verified at scale

Two threads landing together — the doc edits interleave so they ship
in a single commit.

1. **vectord substrate fix verified at original scale** (closes the
   2026-05-01 thread). Re-ran multitier 5min @ conc=50: 132,211
   scenarios at 438/sec, 6/6 classes at 0% failure (was 4/6 pre-fix).
   Throughput dropped 1,115 → 438/sec because previously-broken
   scenarios now do real HNSW Add work — honest cost of correctness.
   The fix (i.vectors side-store + safeGraphAdd recover wrappers +
   smallIndexRebuildThreshold=32 + saveTask coalescing) holds at the
   footprint that originally surfaced the bug.

2. **Materializer port** — internal/materializer + cmd/materializer +
   scripts/materializer_smoke.sh. Ports scripts/distillation/transforms.ts
   (12 transforms) + build_evidence_index.ts (idempotency, day-partition,
   receipt). On-wire JSON shape matches TS so Bun and Go runs are
   interchangeable. 14 tests green.

3. **Replay port** — internal/replay + cmd/replay +
   scripts/replay_smoke.sh. Ports scripts/distillation/replay.ts
   (retrieve → bundle → /v1/chat → validate → log). Closes audit-FULL
   phase 7 live invocation on the Go side. Both runtimes append to the
   same data/_kb/replay_runs.jsonl (schema=replay_run.v1). 14 tests green.

Side effect on internal/distillation/types.go: EvidenceRecord gained
prompt_tokens, completion_tokens, and metadata fields to mirror the TS
shape the materializer transforms produce.

STATE_OF_PLAY refreshed to 2026-05-02; ARCHITECTURE_COMPARISON decisions
tracker moves the materializer + replay items from _open_ to DONE and
adds the substrate-fix scale verification row.

Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>

cmd/vectord/main_test.go

@@ -3,11 +3,15 @@ package main
 import (
 	"bytes"
 	"encoding/json"
+	"errors"
 	"net/http"
 	"net/http/httptest"
 	"strconv"
 	"strings"
+	"sync"
+	"sync/atomic"
 	"testing"
+	"time"
 
 	"github.com/go-chi/chi/v5"
 
@@ -417,3 +421,105 @@ func TestSearchK_DefaultsAndMax(t *testing.T) {
 		t.Errorf("maxK=%d unreasonably large", maxK)
 	}
 }
+
+// TestSaveTask_Coalesces locks the multitier_100k follow-up: a
+// burst of triggers must collapse into at most 2 actual saves
+// (the in-flight one + one catch-up). Without coalescing, every
+// trigger would yield a save and concurrent writers would
+// serialize on the index RLock during Encode (the original
+// 1-2.5s tail-latency cause).
+func TestSaveTask_Coalesces(t *testing.T) {
+	var (
+		s        saveTask
+		saveCnt  atomic.Int32
+		started  = make(chan struct{}, 1)
+		release  = make(chan struct{})
+	)
+	save := func() error {
+		// First save blocks until released so we can pile up
+		// triggers behind it. Subsequent saves return fast so the
+		// catch-up logic completes promptly.
+		n := saveCnt.Add(1)
+		if n == 1 {
+			started <- struct{}{}
+			<-release
+		}
+		return nil
+	}
+	// Trigger first save and wait for it to enter the blocked region.
+	s.trigger(save)
+	<-started
+	// Pile up triggers while the first is blocked. None of these
+	// should start their own goroutines — they should mark "pending".
+	for i := 0; i < 50; i++ {
+		s.trigger(save)
+	}
+	// Release the first save. The trigger logic should run ONE
+	// catch-up save for all 50 piled-up triggers, then return.
+	close(release)
+	// Wait for the goroutine to drain.
+	deadline := time.Now().Add(2 * time.Second)
+	for time.Now().Before(deadline) {
+		s.mu.Lock()
+		idle := !s.inflight && !s.pending
+		s.mu.Unlock()
+		if idle {
+			break
+		}
+		time.Sleep(5 * time.Millisecond)
+	}
+	got := saveCnt.Load()
+	if got != 2 {
+		t.Errorf("save count = %d, want 2 (one in-flight + one catch-up)", got)
+	}
+}
+
+// TestSaveTask_RunsOnce — single trigger fires exactly one save.
+func TestSaveTask_RunsOnce(t *testing.T) {
+	var s saveTask
+	var n atomic.Int32
+	done := make(chan struct{})
+	s.trigger(func() error {
+		n.Add(1)
+		close(done)
+		return nil
+	})
+	select {
+	case <-done:
+	case <-time.After(2 * time.Second):
+		t.Fatal("trigger goroutine never ran")
+	}
+	// Wait briefly for the goroutine to mark inflight=false.
+	time.Sleep(20 * time.Millisecond)
+	if got := n.Load(); got != 1 {
+		t.Errorf("save count = %d, want 1", got)
+	}
+}
+
+// TestSaveTask_LogsSaveError — a save error doesn't break the
+// coalescing state machine; subsequent triggers still work.
+func TestSaveTask_LogsSaveError(t *testing.T) {
+	var s saveTask
+	var n atomic.Int32
+	wantErr := errors.New("boom")
+	var wg sync.WaitGroup
+	wg.Add(1)
+	s.trigger(func() error {
+		defer wg.Done()
+		n.Add(1)
+		return wantErr
+	})
+	wg.Wait()
+	// State must reset so the next trigger fires another save.
+	time.Sleep(20 * time.Millisecond)
+	wg.Add(1)
+	s.trigger(func() error {
+		defer wg.Done()
+		n.Add(1)
+		return nil
+	})
+	wg.Wait()
+	if got := n.Load(); got != 2 {
+		t.Errorf("save count = %d, want 2 (failure must not stall the task)", got)
+	}
+}