fix(engine): recover audio duration via full packet scan when the container header has none

packages/engine/src/utils/ffprobe.test.ts

@@ -861,6 +861,154 @@ describe("ffprobe missing-binary fallback", () => {
   });
 });
 
+// PRINFRA-692: a browser MediaRecorder-produced WebM (or any encode to a
+// non-seekable destination) never gets a Duration element patched back into
+// its header, so ffprobe reports no duration at format OR stream level — not
+// merely zero. Without a fallback, extractAudioMetadata returns
+// durationSeconds: 0, and the render pipeline silently drops the whole audio
+// track (htmlCompiler / audioMixer both treat a non-positive duration as "no
+// usable audio"). These tests cover the packet-timestamp EOF scan that
+// recovers the real duration in that case.
+describe("extractAudioMetadata packet-scan duration recovery (no format.duration at all)", () => {
+  afterEach(() => {
+    vi.resetModules();
+    vi.doUnmock("child_process");
+  });
+
+  const opusStreamNoDuration = (streamDuration?: string) =>
+    JSON.stringify({
+      streams: [
+        {
+          codec_type: "audio",
+          codec_name: "opus",
+          sample_rate: "48000",
+          channels: 1,
+          duration: streamDuration,
+        },
+      ],
+      format: {},
+    });
+
+  async function probe(outcomes: SpawnOutcome[], file: string) {
+    const { spawn, calls } = createSpawnSpy(outcomes);
+    vi.resetModules();
+    vi.doMock("child_process", () => ({ spawn }));
+    const { extractAudioMetadata } = await import("./ffprobe.js");
+    return { meta: await extractAudioMetadata(file), calls };
+  }
+
+  it("recovers duration from the last packet's pts_time + duration_time", async () => {
+    const { meta, calls } = await probe(
+      [
+        { kind: "exit", code: 0, stdout: opusStreamNoDuration(undefined) },
+        {
+          kind: "exit",
+          code: 0,
+          stdout: "0.000000,0.020000\n0.020000,0.020000\n4.994000,0.020000\n",
+        },
+      ],
+      "/tmp/streamed-no-duration.webm",
+    );
+    expect(meta.durationSeconds).toBeCloseTo(5.014, 6);
+    expect(calls).toHaveLength(2);
+  });
+
+  it("prefers the cheap stream-level duration over the packet scan when present", async () => {
+    const { meta, calls } = await probe(
+      [{ kind: "exit", code: 0, stdout: opusStreamNoDuration("5.008000") }],
+      "/tmp/has-stream-duration.webm",
+    );
+    expect(meta.durationSeconds).toBe(5.008);
+    // The packet-scan probe is never attempted — the stream field was enough.
+    expect(calls).toHaveLength(1);
+  });
+
+  it("keeps duration at 0 when the packet scan finds no parseable packets", async () => {
+    const { meta } = await probe(
+      [
+        { kind: "exit", code: 0, stdout: opusStreamNoDuration(undefined) },
+        { kind: "exit", code: 0, stdout: "" },
+      ],
+      "/tmp/streamed-empty-scan.webm",
+    );
+    expect(meta.durationSeconds).toBe(0);
+  });
+
+  it("keeps duration at 0 (never throws) when the packet-scan probe itself fails", async () => {
+    const { meta } = await probe(
+      [
+        { kind: "exit", code: 0, stdout: opusStreamNoDuration(undefined) },
+        { kind: "exit", code: 1, stdout: "", stderr: "ffprobe exploded mid-scan" },
+      ],
+      "/tmp/streamed-scan-fails.webm",
+    );
+    expect(meta.durationSeconds).toBe(0);
+  });
+
+  it("falls back to a bare pts_time when ffprobe reports duration_time as N/A", async () => {
+    const { meta } = await probe(
+      [
+        { kind: "exit", code: 0, stdout: opusStreamNoDuration(undefined) },
+        { kind: "exit", code: 0, stdout: "0.000000,N/A\n4.994000,N/A\n" },
+      ],
+      "/tmp/streamed-no-packet-duration.webm",
+    );
+    expect(meta.durationSeconds).toBeCloseTo(4.994, 6);
+  });
+
+  // Regression: retainTail keeps only the trailing 64 KB of a long probe's
+  // stdout, which for a large file slices through the MIDDLE of an early
+  // line rather than on a line boundary — e.g. "58234.123456,0.02" truncated
+  // to "123456,0.02", a finite but wildly wrong pts. Taking the max across
+  // every parsed line (instead of trusting only the true last line, which is
+  // never truncated since it's flush against the real end of the output)
+  // would let that corrupted fragment silently win over the correct answer —
+  // a confidently-wrong non-zero duration, worse than the 0 this fallback
+  // exists to fix.
+  it("ignores a bogus huge pts from a truncated leading line and trusts only the true last line", async () => {
+    const { meta } = await probe(
+      [
+        { kind: "exit", code: 0, stdout: opusStreamNoDuration(undefined) },
+        {
+          kind: "exit",
+          code: 0,
+          // First line simulates a retainTail truncation artifact: a huge,
+          // finite-but-bogus pts (would win any max()-based reduction).
+          stdout: "123456.000000,0.020000\n4.994000,0.020000\n",
+        },
+      ],
+      "/tmp/streamed-truncated-leading-line.webm",
+    );
+    expect(meta.durationSeconds).toBeCloseTo(5.014, 6);
+  });
+
+  it("does not run the generic packet scan when the AAC-LC refinement already recovered a duration", async () => {
+    const { meta, calls } = await probe(
+      [
+        {
+          kind: "exit",
+          code: 0,
+          stdout: JSON.stringify({
+            streams: [
+              { codec_type: "audio", codec_name: "aac", sample_rate: "44100", profile: "LC" },
+            ],
+            format: {},
+          }),
+        },
+        {
+          kind: "exit",
+          code: 0,
+          stdout: JSON.stringify({ streams: [{ nb_read_packets: "861" }], format: {} }),
+        },
+      ],
+      "/tmp/aac-lc-no-format-duration.m4a",
+    );
+    expect(meta.durationSeconds).toBeCloseTo((861 * 1024) / 44100, 5);
+    // Only the AAC-LC packet-count probe ran — the generic scan was unnecessary.
+    expect(calls).toHaveLength(2);
+  });
+});
+
 describe("ffprobe option separator", () => {
   afterEach(() => {
     vi.resetModules();

packages/engine/src/utils/ffprobe.ts

@@ -910,6 +910,67 @@ export async function extractFinalVideoFrameTimestamp(
  */
 export const extractVideoMetadata = extractMediaMetadata;
 
+/**
+ * Recover audio duration by reading every packet's timestamp to EOF, for
+ * containers that never got a header-level duration written at all — e.g. a
+ * browser `MediaRecorder`-produced WebM (or any encode to a non-seekable
+ * destination): the encoder can't seek back to patch the Segment `Duration`
+ * element in after the fact, so ffprobe reports no duration at format OR
+ * stream level, not merely zero. Unlike the AAC-LC packet-COUNT refinement
+ * above, this doesn't assume a fixed samples-per-packet framing, so it works
+ * for any codec: it takes the latest packet's `pts_time + duration_time` (or
+ * just `pts_time` if a codec/container doesn't report per-packet duration).
+ * Same constraints as the refinement above — never throws (a failed/timed-out
+ * scan just leaves durationSeconds at 0, exactly as before this fallback
+ * existed) and honours the caller's AbortSignal.
+ */
+async function recoverAudioDurationFromPacketScan(
+  filePath: string,
+  signal?: AbortSignal,
+): Promise<number | undefined> {
+  try {
+    const stdout = await runFfprobe(
+      filePath,
+      [
+        "-select_streams",
+        "a:0",
+        "-show_entries",
+        "packet=pts_time,duration_time",
+        "-of",
+        "csv=p=0",
+      ],
+      signal,
+      { retainTail: true, maxChars: 64 * 1024 },
+    );
+    // Only the LAST parsed line is trusted, mirroring
+    // extractFinalVideoFrameTimestamp's parseFinalTimestamp above (same
+    // retainTail/maxChars config, same reason): retainTail keeps only the
+    // trailing bytes of a long probe, which can slice through the MIDDLE of
+    // an early line and leave a numerically-bogus fragment (e.g.
+    // "58234.123456" truncated to "123456" — a finite but wildly wrong
+    // number) — but never through the true last line, which is flush against
+    // the real end of ffprobe's output. Taking the max across every parsed
+    // line instead of the true last one would let a truncation artifact like
+    // that silently win over the correct answer.
+    return stdout
+      .split("\n")
+      .map((line) => line.trim())
+      .filter((line) => line.length > 0)
+      .map((line) => {
+        const [ptsText, durationText] = line.split(",");
+        return { pts: Number(ptsText), duration: Number(durationText) };
+      })
+      .filter(({ pts }) => Number.isFinite(pts))
+      .map(({ pts, duration }) => pts + (Number.isFinite(duration) ? duration : 0))
+      .at(-1);
+  } catch (error) {
+    // An abort is the caller's intent, not a recovery failure — let it
+    // through. Anything else leaves durationSeconds at 0, same as before.
+    if (signal?.aborted) throw error;
+    return undefined;
+  }
+}
+
 export async function extractAudioMetadata(
   filePath: string,
   options?: { signal?: AbortSignal },
@@ -927,6 +988,8 @@ export async function extractAudioMetadata(
 
     let durationSeconds = output.format.duration ? parseFloat(output.format.duration) : 0;
     const streamDuration = audioStream.duration ? parseFloat(audioStream.duration) : undefined;
+    const usableStreamDuration =
+      streamDuration !== undefined && streamDuration > 0 ? streamDuration : undefined;
     const sampleRate = audioStream.sample_rate ? parseInt(audioStream.sample_rate) : 44100;
     const audioCodec = audioStream.codec_name || "unknown";
     // AAC-LC container durations are often slightly wrong, so the packet
@@ -985,9 +1048,23 @@ export async function extractAudioMetadata(
       }
     }
 
+    // Neither format.duration nor the AAC-LC refinement above produced a
+    // usable duration — a non-seekable-origin container (PRINFRA-692) most
+    // likely. Prefer the cheap, already-parsed stream-level duration if the
+    // container happened to carry one; otherwise recover it with a full
+    // packet-timestamp scan.
+    if (durationSeconds <= 0) {
+      if (usableStreamDuration !== undefined) {
+        durationSeconds = usableStreamDuration;
+      } else {
+        const recovered = await recoverAudioDurationFromPacketScan(filePath, options?.signal);
+        if (recovered !== undefined && recovered > 0) durationSeconds = recovered;
+      }
+    }
+
     return {
       durationSeconds,
-      streamDurationSeconds: streamDuration && streamDuration > 0 ? streamDuration : undefined,
+      streamDurationSeconds: usableStreamDuration,
       sampleRate,
       channels: audioStream.channels || 2,
       audioCodec,