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itkMCI_DSC_case_2_binary: crashes on Windows nightly, intermittently aborts on macOS CI #6448

Description

@hjmjohnson

itkMCI_DSC_case_2_binary (MorphologicalContourInterpolation remote module) is failing on the dashboard: consistently on Windows nightlies and intermittently (abort) on macOS CI. It is not currently tracked.

Evidence

Windows nightly (ryzenator.kitware) — 60/60 most recent CDash records for this test are Failed, failing fast (~0.05–0.28 s):

  • Windows11-VS2022-Static-DebugTBB
  • Windows11-VS22x64-RelWithDebInfo-Favorite-Remotes

macOS CI (GitHub Actions, ITK.Pixi Pixi-Cxx (macos-15)) — usually passes (~187–220 s) but intermittently aborts:

Test #5545: itkMCI_DSC_case_2_binary ... Subprocess aborted ***Exception: 196.99 sec

The abort happens after a full-length run (~197 s, its normal duration), so this is not a timeout (ctest budget is 1500 s) — it is a SIGABRT (uncaught exception / assert / libc++ abort) at the end of the run. It cleared on rerun.

Notes

  • The sibling test itkMCI_DSC_case_2_labels passes (~104 s). Only the _binary variant is affected.
  • The two platforms fail differently (Windows fails instantly; macOS aborts after a full run), which may indicate more than one underlying problem.
  • CI runs ctest -j without --output-on-failure for these, so the aborting test's stdout/stderr is not captured — the exact exception message is unknown from CI logs alone.

Suspected

Memory or undefined-behavior bug in the binary-DSC path of the MCI algorithm (manifesting as a hard crash on Windows and an intermittent abort on macOS). Investigation under ASan/UBSan is in progress.

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