Fix Windows CI flake hardening (#1325)

* fix windows ci test flake hardening

* restore required test check status

.github/workflows/ci.yml

@@ -40,48 +40,11 @@ jobs:
               - 'scripts/update-flake.sh'
               - '.github/workflows/ci.yml'
 
-  test_pr:
-    name: Test
-    runs-on: ubuntu-latest
-    timeout-minutes: 10
-    if: github.event_name == 'pull_request' || github.event_name == 'merge_group'
-
-    steps:
-      - name: Checkout code
-        uses: actions/checkout@v4
-        with:
-          fetch-depth: 0
-
-      - name: Setup pnpm
-        uses: pnpm/action-setup@v4
-
-      - name: Setup Node.js
-        uses: actions/setup-node@v4
-        with:
-          node-version: '20.19.0'
-          cache: 'pnpm'
-
-      - name: Install dependencies
-        run: pnpm install --frozen-lockfile
-
-      - name: Build project
-        run: pnpm run build
-
-      - name: Run tests
-        run: pnpm test
-
-      - name: Upload test coverage
-        uses: actions/upload-artifact@v4
-        with:
-          name: coverage-report-pr
-          path: coverage/
-          retention-days: 7
-
   test_matrix:
     name: Test (${{ matrix.label }})
     runs-on: ${{ matrix.os }}
     timeout-minutes: 15
-    if: github.event_name == 'push' || github.event_name == 'workflow_dispatch'
+    if: github.event_name == 'pull_request' || github.event_name == 'merge_group' || github.event_name == 'push' || github.event_name == 'workflow_dispatch'
     strategy:
       fail-fast: false
       matrix:
@@ -89,12 +52,15 @@ jobs:
           - os: ubuntu-latest
             shell: bash
             label: linux-bash
+            vitest_workers: 4
           - os: macos-latest
             shell: bash
             label: macos-bash
+            vitest_workers: 4
           - os: windows-latest
             shell: pwsh
             label: windows-pwsh
+            vitest_workers: 2
 
     defaults:
       run:
@@ -126,16 +92,32 @@ jobs:
         run: pnpm run build
 
       - name: Run tests
+        env:
+          VITEST_MAX_WORKERS: ${{ matrix.vitest_workers }}
         run: pnpm test
 
       - name: Upload test coverage
         if: matrix.os == 'ubuntu-latest'
         uses: actions/upload-artifact@v4
         with:
-          name: coverage-report-main
+          name: coverage-report-${{ github.event_name }}
           path: coverage/
           retention-days: 7
 
+  test_pr_required:
+    name: Test
+    runs-on: ubuntu-latest
+    needs: [test_matrix]
+    if: always() && (github.event_name == 'pull_request' || github.event_name == 'merge_group')
+    steps:
+      - name: Verify matrix tests passed
+        run: |
+          if [[ "${{ needs.test_matrix.result }}" != "success" ]]; then
+            echo "Matrix test job failed"
+            exit 1
+          fi
+          echo "All matrix tests passed!"
+
   lint:
     name: Lint & Type Check
     runs-on: ubuntu-latest
@@ -288,13 +270,13 @@ jobs:
   required-checks-pr:
     name: All checks passed
     runs-on: ubuntu-latest
-    needs: [test_pr, lint, nix-flake-validate]
+    needs: [test_matrix, lint, nix-flake-validate]
     if: always() && (github.event_name == 'pull_request' || github.event_name == 'merge_group')
     steps:
       - name: Verify all checks passed
         run: |
-          if [[ "${{ needs.test_pr.result }}" != "success" ]]; then
-            echo "Test job failed"
+          if [[ "${{ needs.test_matrix.result }}" != "success" ]]; then
+            echo "Matrix test job failed"
             exit 1
           fi
           if [[ "${{ needs.lint.result }}" != "success" ]]; then

test/cli-e2e/capstone-journeys.test.ts

@@ -6,6 +6,9 @@ import * as path from 'node:path';
 import { getGlobalDataDir, registerStore } from '../../src/core/index.js';
 import { runCLI } from '../helpers/run-cli.js';
 import { createOpenSpecRoot, writeSpec } from '../helpers/openspec-fixtures.js';
+import { cleanupTempPath } from '../helpers/temp-cleanup.js';
+
+const JOURNEY_TIMEOUT_MS = 30_000;
 
 /**
  * Capstone persona journeys (6.1). Journey 1 (fresh team) lives in
@@ -31,7 +34,7 @@ describe('capstone persona journeys (6.1)', () => {
   });
 
   afterEach(() => {
-    fs.rmSync(tempDir, { recursive: true, force: true });
+    cleanupTempPath(tempDir);
   });
 
   it('journey 2 — layered flow: app-repo agent discovers, cites, designs locally', async () => {
@@ -97,7 +100,7 @@ describe('capstone persona journeys (6.1)', () => {
     // The store stayed read-only context throughout.
     const storeChanges = fs.readdirSync(path.join(storeRoot, 'openspec', 'changes'));
     expect(storeChanges.filter((name) => name !== 'archive' && name !== '.gitkeep')).toEqual([]);
-  });
+  }, JOURNEY_TIMEOUT_MS);
 
   it('journey 3 — externalized planning: pointer repo runs the lifecycle without --store', async () => {
     const storeRoot = path.join(tempDir, 'team-planning');
@@ -174,5 +177,5 @@ describe('capstone persona journeys (6.1)', () => {
 
     // The code repo never grew planning state.
     expect(fs.readdirSync(path.join(codeRepo, 'openspec'))).toEqual(['config.yaml']);
-  });
+  }, JOURNEY_TIMEOUT_MS);
 });

test/cli-e2e/store-lifecycle.test.ts

@@ -5,6 +5,7 @@ import path from 'path';
 import { tmpdir } from 'os';
 import { promisify } from 'util';
 import { runCLI } from '../helpers/run-cli.js';
+import { cleanupTempPath } from '../helpers/temp-cleanup.js';
 
 const execFileAsync = promisify(execFile);
 
@@ -18,6 +19,7 @@ const execFileAsync = promisify(execFile);
  */
 
 const STORE_ID = 'team-context';
+const JOURNEY_TIMEOUT_MS = 60_000;
 
 let base: string;
 let storeRoot: string;
@@ -189,7 +191,7 @@ beforeAll(async () => {
 }, 120_000);
 
 afterAll(async () => {
-  await fs.rm(base, { recursive: true, force: true });
+  cleanupTempPath(base);
 });
 
 describe('standalone store lifecycle journey', () => {
@@ -337,7 +339,7 @@ describe('standalone store lifecycle journey', () => {
       path.join(storeRoot, 'openspec', 'changes', 'archive')
     );
     expect(archiveEntries.some((entry) => entry.endsWith(`-${changeId}`))).toBe(true);
-  });
+  }, JOURNEY_TIMEOUT_MS);
 
   it('machine A: the project repo is byte-identical after the lifecycle', async () => {
     const after = await snapshotDirectory(projectDir);
@@ -391,7 +393,7 @@ describe('standalone store lifecycle journey', () => {
     );
     expect(shownSpec.exitCode).toBe(0);
     expect(shownSpec.stdout).toContain('billing SHALL work');
-  });
+  }, JOURNEY_TIMEOUT_MS);
 
   it('machine B: completes its own change through archive in the clone', async () => {
     const changeId = 'add-invoicing';
@@ -450,7 +452,7 @@ describe('standalone store lifecycle journey', () => {
     expect(failedApply.exitCode).not.toBe(0);
     expect(failedApply.stderr).toContain(`Using OpenSpec root: ${STORE_ID}`);
     expect(failedApply.stderr).toContain(`openspec new change <name> --store ${STORE_ID}`);
-  });
+  }, JOURNEY_TIMEOUT_MS);
 
   it('end state is just normal OpenSpec files in both checkouts', async () => {
     for (const root of [storeRoot, cloneRoot]) {

test/commands/context.test.ts

@@ -7,6 +7,9 @@ import { getGlobalDataDir, registerStore } from '../../src/core/index.js';
 import { runCLI, type RunCLIResult } from '../helpers/run-cli.js';
 import { createOpenSpecRoot } from '../helpers/openspec-fixtures.js';
 import { snapshotDirectory as snapshot } from '../helpers/fs-snapshot.js';
+import { cleanupTempPath } from '../helpers/temp-cleanup.js';
+
+const CONTEXT_MATRIX_TIMEOUT_MS = 30_000;
 
 describe('openspec context (4.1)', () => {
   let tempDir: string;
@@ -41,7 +44,7 @@ describe('openspec context (4.1)', () => {
   });
 
   afterEach(() => {
-    fs.rmSync(tempDir, { recursive: true, force: true });
+    cleanupTempPath(tempDir);
   });
 
   function parseJson(result: RunCLIResult): any {
@@ -193,7 +196,7 @@ describe('openspec context (4.1)', () => {
     );
     expect(jsonBadDir.exitCode).toBe(1);
     expect(JSON.parse(jsonBadDir.stdout).status[0].code).toBe('context_output_dir_missing');
-  });
+  }, CONTEXT_MATRIX_TIMEOUT_MS);
 
   it('is read-only except the requested file and fails with the null shape', async () => {
     const rootBefore = snapshot(storeRoot);

test/commands/doctor.test.ts

@@ -7,6 +7,7 @@ import { getGlobalDataDir, registerStore } from '../../src/core/index.js';
 import { runCLI, type RunCLIResult } from '../helpers/run-cli.js';
 import { createOpenSpecRoot, writeSpec } from '../helpers/openspec-fixtures.js';
 import { snapshotDirectory as snapshot } from '../helpers/fs-snapshot.js';
+import { cleanupTempPath } from '../helpers/temp-cleanup.js';
 
 describe('openspec doctor (3.6)', () => {
   let tempDir: string;
@@ -30,7 +31,7 @@ describe('openspec doctor (3.6)', () => {
   });
 
   afterEach(() => {
-    fs.rmSync(tempDir, { recursive: true, force: true });
+    cleanupTempPath(tempDir);
   });
 
   function parseJson(result: RunCLIResult): any {

test/commands/legacy-groups-removed.test.ts

@@ -6,6 +6,9 @@ import * as path from 'node:path';
 import { getGlobalDataDir, registerStore } from '../../src/core/index.js';
 import { runCLI } from '../helpers/run-cli.js';
 import { createHealthyOpenSpecRoot } from '../helpers/store-git.js';
+import { cleanupTempPath } from '../helpers/temp-cleanup.js';
+
+const SURVIVING_COMMANDS_TIMEOUT_MS = 30_000;
 
 describe('legacy command groups are removed', () => {
   let tempDir: string;
@@ -24,7 +27,7 @@ describe('legacy command groups are removed', () => {
   });
 
   afterEach(() => {
-    fs.rmSync(tempDir, { recursive: true, force: true });
+    cleanupTempPath(tempDir);
   });
 
   function snapshotDirectory(root: string): Map<string, string> {
@@ -139,7 +142,7 @@ describe('legacy command groups are removed', () => {
 
     expect(snapshotDirectory(path.join(storeRoot, 'initiatives'))).toEqual(initiativeBefore);
     expect(snapshotDirectory(path.join(projectDir, '.openspec-workspace'))).toEqual(viewBefore);
-  });
+  }, SURVIVING_COMMANDS_TIMEOUT_MS);
 
   it('tolerates legacy initiative metadata without re-emitting it', async () => {
     const projectDir = path.join(tempDir, 'legacy-project');

test/commands/store-git.test.ts

@@ -12,6 +12,7 @@ import {
 } from '../../src/core/index.js';
 import { runCLI, type RunCLIResult } from '../helpers/run-cli.js';
 import { createHealthyOpenSpecRoot, isolatedGitEnv } from '../helpers/store-git.js';
+import { cleanupTempPath } from '../helpers/temp-cleanup.js';
 
 vi.mock('@inquirer/prompts', () => ({
   input: vi.fn(),
@@ -82,7 +83,7 @@ describe('store git lifecycle', () => {
     consoleLogSpy?.mockRestore();
     consoleErrorSpy?.mockRestore();
     vi.clearAllMocks();
-    fs.rmSync(tempDir, { recursive: true, force: true });
+    cleanupTempPath(tempDir);
   });
 
   function mkdir(relativePath: string): string {

test/commands/store-remote.test.ts

@@ -12,8 +12,10 @@ import {
 } from '../../src/core/index.js';
 import { runCLI, type RunCLIResult } from '../helpers/run-cli.js';
 import { createHealthyOpenSpecRoot, isolatedGitEnv } from '../helpers/store-git.js';
+import { cleanupTempPath } from '../helpers/temp-cleanup.js';
 
 const TEST_NET_URL = 'https://192.0.2.1/acme/team-context.git';
+const GIT_JOURNEY_TIMEOUT_MS = 60_000;
 
 describe('store canonical remote (3.3)', () => {
   let tempDir: string;
@@ -33,7 +35,7 @@ describe('store canonical remote (3.3)', () => {
   });
 
   afterEach(() => {
-    fs.rmSync(tempDir, { recursive: true, force: true });
+    cleanupTempPath(tempDir);
   });
 
   function git(cwd: string, ...args: string[]): string {
@@ -419,7 +421,7 @@ describe('store canonical remote (3.3)', () => {
       const resolvedEntry = parseJson(resolved).references[0];
       expect(resolvedEntry.status).toEqual([]);
       expect(resolvedEntry.root).toBe(fs.realpathSync.native(expectedCheckout));
-    });
+    }, GIT_JOURNEY_TIMEOUT_MS);
   });
 
   describe('doctor and resolution', () => {

test/commands/store-root-selection.test.ts

@@ -9,6 +9,7 @@ import {
 } from '../../src/core/index.js';
 import { writeStoreMetadataState } from '../../src/core/store/foundation.js';
 import { runCLI, type RunCLIResult } from '../helpers/run-cli.js';
+import { cleanupTempPath } from '../helpers/temp-cleanup.js';
 
 const VALID_DELTA_SPEC = `## ADDED Requirements
 
@@ -69,7 +70,7 @@ describe('store root selection for normal commands', () => {
   });
 
   afterEach(() => {
-    fs.rmSync(tempDir, { recursive: true, force: true });
+    cleanupTempPath(tempDir);
   });
 
   function createOpenSpecRoot(rootDir: string): void {

test/commands/workset.test.ts

@@ -16,6 +16,7 @@ import {
 import { runCLI, type RunCLIResult } from '../helpers/run-cli.js';
 import { createFakeTool, envWithFakeTools, readLaunchLog } from '../helpers/fake-tool.js';
 import { snapshotDirectory as snapshot } from '../helpers/fs-snapshot.js';
+import { cleanupTempPath } from '../helpers/temp-cleanup.js';
 
 describe('openspec workset (7.1)', () => {
   let tempDir: string;
@@ -56,7 +57,7 @@ describe('openspec workset (7.1)', () => {
 
   afterEach(() => {
     delete process.env.OPENSPEC_ENABLE_CLI_AGENT_OPENERS;
-    fs.rmSync(tempDir, { recursive: true, force: true });
+    cleanupTempPath(tempDir);
   });
 
   function parseJson(result: RunCLIResult): any {
@@ -469,7 +470,7 @@ describe('openspec workset (7.1)', () => {
     it('skips a missing member and falls through to the next primary', async () => {
       await createPlatform(['--tool', 'claude']);
       const fakeClaude = createFakeTool(tempDir, 'claude');
-      fs.rmSync(memberB, { recursive: true, force: true });
+      cleanupTempPath(memberB);
 
       const result = await runCLI(['workset', 'open', 'platform'], {
         cwd: tempDir,
@@ -494,7 +495,7 @@ describe('openspec workset (7.1)', () => {
 
       // Primary missing: the next surviving member becomes cwd, and
       // the reassignment is noted in the skip-line style.
-      fs.rmSync(memberA, { recursive: true, force: true });
+      cleanupTempPath(memberA);
       const second = await runCLI(['workset', 'open', 'platform'], {
         cwd: tempDir,
         env: envWithFakeTools(env, [fakeClaude]),
@@ -508,7 +509,7 @@ describe('openspec workset (7.1)', () => {
       );
 
       // No member survives: a typed failure.
-      fs.rmSync(memberC, { recursive: true, force: true });
+      cleanupTempPath(memberC);
       const third = await runCLI(['workset', 'open', 'platform'], {
         cwd: tempDir,
         env: envWithFakeTools(env, [fakeClaude]),
@@ -871,7 +872,7 @@ describe('interactive compose cancellation (in-process)', () => {
     restoreTTY?.();
     process.env = originalEnv;
     process.exitCode = originalExitCode;
-    fs.rmSync(tempDir, { recursive: true, force: true });
+    cleanupTempPath(tempDir);
   });
 
   function exitPromptError(): Error {

test/helpers/run-cli.ts

@@ -1,4 +1,4 @@
-import { spawn } from 'child_process';
+import { type ChildProcess, spawn } from 'child_process';
 import { existsSync } from 'fs';
 import path from 'path';
 import { fileURLToPath } from 'url';
@@ -8,8 +8,10 @@ const __dirname = path.dirname(__filename);
 
 const projectRoot = path.resolve(__dirname, '..', '..');
 const cliEntry = path.join(projectRoot, 'dist', 'cli', 'index.js');
+const DEFAULT_CLI_TIMEOUT_MS = 30_000;
 
 let buildPromise: Promise<void> | undefined;
+const activeCliChildren = new Set<ChildProcess>();
 
 interface RunCommandOptions {
   cwd?: string;
@@ -53,6 +55,65 @@ function runCommand(command: string, args: string[], options: RunCommandOptions
   });
 }
 
+function mergeEnv(
+  ...sources: Array<NodeJS.ProcessEnv | undefined>
+): NodeJS.ProcessEnv {
+  const merged: NodeJS.ProcessEnv = {};
+
+  for (const source of sources) {
+    if (!source) continue;
+    for (const [key, value] of Object.entries(source)) {
+      if (value === undefined) continue;
+
+      if (process.platform === 'win32') {
+        const existingKey = Object.keys(merged).find(
+          (candidate) => candidate.toLowerCase() === key.toLowerCase()
+        );
+        if (existingKey && existingKey !== key) {
+          delete merged[existingKey];
+        }
+      }
+
+      merged[key] = value;
+    }
+  }
+
+  return merged;
+}
+
+function terminateProcessTree(child: ChildProcess): void {
+  if (!child.pid || child.killed) {
+    return;
+  }
+
+  if (process.platform === 'win32') {
+    spawn('taskkill', ['/pid', String(child.pid), '/t', '/f'], {
+      stdio: 'ignore',
+      windowsHide: true,
+    }).on('error', () => {
+      child.kill('SIGKILL');
+    });
+    return;
+  }
+
+  try {
+    process.kill(-child.pid, 'SIGKILL');
+  } catch {
+    child.kill('SIGKILL');
+  }
+}
+
+function formatOutputTail(output: string): string {
+  const lines = output.trimEnd().split(/\r?\n/);
+  return lines.slice(-20).join('\n');
+}
+
+export function terminateActiveCliChildren(): void {
+  for (const child of activeCliChildren) {
+    terminateProcessTree(child);
+  }
+}
+
 export async function ensureCliBuilt() {
   if (existsSync(cliEntry)) {
     return;
@@ -79,30 +140,34 @@ export async function runCLI(args: string[] = [], options: RunCLIOptions = {}):
   const invocation = [cliEntry, ...finalArgs].join(' ');
 
   return new Promise<RunCLIResult>((resolve, reject) => {
+    const timeoutMs = options.timeoutMs ?? DEFAULT_CLI_TIMEOUT_MS;
     const child = spawn(process.execPath, [cliEntry, ...finalArgs], {
       cwd: options.cwd ?? projectRoot,
-      env: {
-        ...process.env,
-        OPEN_SPEC_INTERACTIVE: '0',
-        ...options.env,
-      },
+      env: mergeEnv(
+        process.env,
+        {
+          OPENSPEC_TELEMETRY: '0',
+          OPEN_SPEC_INTERACTIVE: '0',
+        },
+        options.env
+      ),
       stdio: ['pipe', 'pipe', 'pipe'],
+      detached: process.platform !== 'win32',
       windowsHide: true,
     });
 
     // Prevent child process from keeping the event loop alive
     child.unref();
+    activeCliChildren.add(child);
 
     let stdout = '';
     let stderr = '';
     let timedOut = false;
 
-    const timeout = options.timeoutMs
-      ? setTimeout(() => {
-          timedOut = true;
-          child.kill('SIGKILL');
-        }, options.timeoutMs)
-      : undefined;
+    const timeout = setTimeout(() => {
+      timedOut = true;
+      terminateProcessTree(child);
+    }, timeoutMs);
 
     child.stdout?.setEncoding('utf-8');
     child.stdout?.on('data', (chunk) => {
@@ -115,7 +180,8 @@ export async function runCLI(args: string[] = [], options: RunCLIOptions = {}):
     });
 
     child.on('error', (error) => {
-      if (timeout) clearTimeout(timeout);
+      clearTimeout(timeout);
+      activeCliChildren.delete(child);
       // Explicitly destroy streams to prevent hanging handles
       child.stdout?.destroy();
       child.stderr?.destroy();
@@ -124,11 +190,26 @@ export async function runCLI(args: string[] = [], options: RunCLIOptions = {}):
     });
 
     child.on('close', (code, signal) => {
-      if (timeout) clearTimeout(timeout);
+      clearTimeout(timeout);
+      activeCliChildren.delete(child);
       // Explicitly destroy streams to prevent hanging handles
       child.stdout?.destroy();
       child.stderr?.destroy();
       child.stdin?.destroy();
+      if (timedOut) {
+        reject(
+          new Error(
+            [
+              `CLI command timed out after ${timeoutMs}ms: node ${invocation}`,
+              stderr ? `stderr tail:\n${formatOutputTail(stderr)}` : '',
+              stdout ? `stdout tail:\n${formatOutputTail(stdout)}` : '',
+            ]
+              .filter(Boolean)
+              .join('\n\n')
+          )
+        );
+        return;
+      }
       resolve({
         exitCode: code,
         signal,

test/helpers/temp-cleanup.ts

@@ -0,0 +1,14 @@
+import * as fs from 'node:fs';
+
+export function cleanupTempPath(target: string | undefined): void {
+  if (!target) {
+    return;
+  }
+
+  fs.rmSync(target, {
+    recursive: true,
+    force: true,
+    maxRetries: 5,
+    retryDelay: 100,
+  });
+}

vitest.setup.ts

@@ -1,15 +1,10 @@
-import { ensureCliBuilt } from './test/helpers/run-cli.js';
+import { ensureCliBuilt, terminateActiveCliChildren } from './test/helpers/run-cli.js';
 
 // Ensure the CLI bundle exists before tests execute
 export async function setup() {
   await ensureCliBuilt();
 }
 
-// Global teardown to ensure clean exit
 export async function teardown() {
-  // Force exit after a short grace period if the process hasn't exited cleanly.
-  // This handles cases where child processes or open handles keep the worker alive.
-  setTimeout(() => {
-    process.exit(0);
-  }, 1000).unref();
+  terminateActiveCliChildren();
 }