Reported here https://github.com/bitcoin/bitcoin/pull/12629#issuecomment-381095603 by @Empact.  I've seen it now in a few different travis jobs, including:

https://travis-ci.org/bitcoin/bitcoin/jobs/366157920
https://travis-ci.org/bitcoin/bitcoin/jobs/366139851

From my initial investigation it seems like there may be an actual bug in block announcement, so I'm  opening this issue to track.
if (mi == mapBlockIndex.end())
            return state.DoS(10, error("%s: prev block not found", __func__), 0, "prev-blk-not-found");
        pindexPrev = (*mi).second;
        if (pindexPrev->nStatus & BLOCK_FAILED_MASK)
            return state.DoS(100, error("%s: prev block invalid", __func__), REJECT_INVALID, "bad-prevblk");
        if (!ContextualCheckBlockHeader(block, state, chainparams, pindexPrev, GetAdjustedTime()))
            return error("%s: Consensus::ContextualCheckBlockHeader: %s, %s", __func__, hash.ToString(), FormatStateMessage(state));
        if (!pindexPrev->IsValid(BLOCK_VALID_SCRIPTS)) {
            for (const CBlockIndex* failedit : g_failed_blocks) {
                if (pindexPrev->GetAncestor(failedit->nHeight) == failedit) {
                    assert(failedit->nStatus & BLOCK_FAILED_VALID);
                    CBlockIndex* invalid_walk = pindexPrev;
                    while (invalid_walk != failedit) {
                        invalid_walk->nStatus |= BLOCK_FAILED_CHILD;
                        setDirtyBlockIndex.insert(invalid_walk);
                        invalid_walk = invalid_walk->pprev;
                    }
                    return state.DoS(100, error("%s: prev block invalid", __func__), REJECT_INVALID, "bad-prevblk");
                }
            }
        }
    }
    if (pindex == nullptr)
        pindex = AddToBlockIndex(block);
    if (ppindex)
        *ppindex = pindex;
    CheckBlockIndex(chainparams.GetConsensus());
    return true;
}
bool ProcessNewBlockHeaders(const std::vector<CBlockHeader>& headers, CValidationState& state, const CChainParams& chainparams, const CBlockIndex** ppindex, CBlockHeader *first_invalid)