fix(security): make unsafe env::set_var calls safe with explicit invariants (#968)

* fix(security): make unsafe env::set_var calls safe with explicit invariants

`std::env::set_var` is unsafe in Rust 1.82+ because concurrent calls
from multiple threads cause undefined behavior. This commit addresses
the two production-code call sites:

1. `bootstrap.rs:load_ironclaw_env()` -- called before the Tokio
   runtime starts (genuinely single-threaded). Added a `debug_assert!`
   that verifies no Tokio runtime is active, making the safety
   invariant machine-checkable rather than relying on a comment.

2. `llm/session.rs:api_key_login()` -- was calling `set_var` mid-
   execution inside the multi-threaded Tokio runtime (UB risk).
   Replaced with `set_runtime_env()`, a new thread-safe overlay
   backed by `OnceLock<Mutex<HashMap>>`. The overlay integrates with
   the existing `optional_env()` config resolution and a new
   `env_or_override()` reader function.

All call sites that read `NEARAI_API_KEY` via raw `std::env::var()`
(wizard.rs, main.rs, doctor.rs) are updated to use the thread-safe
`env_or_override()` helper instead, so the value set during
interactive login is visible without mutating the process environment.

Test code `set_var`/`remove_var` calls (bootstrap tests, config tests,
shell tests, oauth tests, wizard tests) are left as-is since they run
under `ENV_MUTEX` serialization and are not production paths.

Co-Authored-By: Claude Sonnet 4.6 <[email protected]>

* fix: address review feedback on thread-safe env overlay PR

- Replace debug_assert! with runtime check in bootstrap.rs so release
  builds skip unsafe set_var when a Tokio runtime is active
- Recover from mutex poison in set_runtime_env instead of silently
  dropping writes (poisoned HashMap is still usable)
- Skip empty override values in env_or_override and optional_env for
  consistency with real env var handling
- Fix doc comment on env_or_override (real env checked first, not
  runtime overrides)
- Update api_key_login doc to describe runtime overlay instead of
  env var mutation

[skip-regression-check]

Co-Authored-By: Claude Sonnet 4.6 <[email protected]>

* fix: use LazyLock::lock() for INJECTED_VARS; use set_runtime_env() in bootstrap fallback

- helpers.rs: fix env_or_override() to call INJECTED_VARS.lock() instead
  of .get() — INJECTED_VARS was changed upstream from OnceLock<HashMap>
  to LazyLock<Mutex<HashMap>>; calling .get() caused a compile error
  (E0599: no method named 'get' for LazyLock)

- bootstrap.rs: when load_ironclaw_env() is called with an active Tokio
  runtime, use set_runtime_env("DATABASE_BACKEND", "libsql") instead of
  silently dropping the write. This ensures DATABASE_BACKEND is always
  set regardless of thread context (addresses ilblackdragon review item 1).

Co-Authored-By: Claude Sonnet 4.6 <[email protected]>

---------

Co-authored-by: Gabe Hamilton <[email protected]>
Co-authored-by: Claude Sonnet 4.6 <[email protected]>

src/setup/wizard.rs

@@ -1183,9 +1183,9 @@ impl SetupWizard {
         self.persist_session_to_db().await;
 
         // If the user chose the API key path, NEARAI_API_KEY is now set
-        // in the environment. Persist it to the encrypted secrets store
-        // so inject_llm_keys_from_secrets() can load it on future runs.
-        if let Ok(api_key) = std::env::var("NEARAI_API_KEY")
+        // in the runtime env overlay. Persist it to the encrypted secrets
+        // store so inject_llm_keys_from_secrets() can load it on future runs.
+        if let Some(api_key) = crate::config::helpers::env_or_override("NEARAI_API_KEY")
             && !api_key.is_empty()
             && let Ok(ctx) = self.init_secrets_context().await
         {
@@ -2613,8 +2613,9 @@ impl SetupWizard {
             env_vars.push((base_url_env.clone(), base_url.clone()));
         }
 
-        // Preserve NEARAI_API_KEY if present (set by API key auth flow)
-        if let Ok(api_key) = std::env::var("NEARAI_API_KEY")
+        // Preserve NEARAI_API_KEY if present (set by API key auth flow
+        // via the thread-safe runtime env overlay).
+        if let Some(api_key) = crate::config::helpers::env_or_override("NEARAI_API_KEY")
             && !api_key.is_empty()
         {
             env_vars.push(("NEARAI_API_KEY".to_string(), api_key));