How is ArrayOutOfBoundsException possible in String.valueOf(int)?

I can reliably reproduce your issue with this code:

public class Main
{
  public static StringBuilder intToString(byte[] bs) {
    final StringBuilder sb = new StringBuilder();
    boolean started = false;
    for (Byte byt : bs) {
      if (started) sb.append(".");
      sb.append(String.valueOf(byt & 0xFF));
      started = true;
    }
    return sb;
  }

  public static void main(String[] args) {
    final byte[] bs = {-2, -1, 0, 1, 2};
    while (true) intToString(bs);
  }
}

The issue will almost certainly be traced to a JIT compiler bug. Your observation that, once it happens the first time, it happens reliably on every subsequent call, points cleanly to a JIT compilation event which introduces the buggy code into the codepath.

If that's available to you, you could activate diagnostic JVM options which will print all compilation events (-XX:PrintCompilation). Then you may be able to correlate such an event with the moment when the exception starts appearing.

I am leaving the code snippet here, as it still ought to be run faster than the original code - at a cost of memory - but be advised it doesn't actually fix the problem.

private static final String[] STRING_CACHE = new String[256];

static {
  for(int i = 0; i <= 255; i++) {
    STRING_CACHE[i] = String.valueOf(i);
  }
}

public static String ipToString(ByteString bs) {
  if (bs == null || bs.isEmpty()) {
    return null;
  } else {
    StringBuilder sb = new StringBuilder();
    boolean started = false;
    for (Byte byt : bs) {
      if (started) {
        sb.append(".");
      }
      sb.append(STRING_CACHE[byt & 0xFF]);
      started = true;
    }

    return sb.toString();
  }
}