fix(macos): treat a vanished DMG mount as detached and force-detach by device node (#156702)

scripts/create-dmg.sh

@@ -124,10 +124,16 @@ DMG_RW_PATH="$DMG_TEMP/image-rw.dmg"
 DMG_OUTPUT_TEMP=""
 DMG_FINAL_PATH=""
 MOUNTED=0
+DMG_DEVICE=""
+
+dmg_attached() {
+  # mount(8) prints resolved paths; the run-private mount suffix still matches.
+  mount | grep -F -e "$MOUNT_POINT" -e "${DMG_DEVICE:-$MOUNT_POINT} on " >/dev/null
+}
 
 cleanup_dmg() {
   if [[ "$MOUNTED" == "1" ]]; then
-    if hdiutil detach "$MOUNT_POINT" -force 2>/dev/null; then
+    if hdiutil detach "${DMG_DEVICE:-$MOUNT_POINT}" -force 2>/dev/null || ! dmg_attached; then
       MOUNTED=0
     else
       echo "WARN: Preserving DMG temp root because mount is still attached: $DMG_TEMP" >&2
@@ -145,17 +151,25 @@ detach_dmg() {
   local delay
   # Mount writers have exited and the shell never enters MOUNT_POINT.
   # Flush writes, then give Finder/Spotlight up to 54s to release the volume.
+  # A volume that vanished on its own (diskarbitration ejected it) is detached.
   sync
   for delay in 2 3 4 5 6 7 8 9 10; do
     sleep "$delay"
-    if hdiutil detach "$MOUNT_POINT" -quiet 2>/dev/null; then
+    if hdiutil detach "$MOUNT_POINT" -quiet 2>/dev/null || ! dmg_attached; then
       MOUNTED=0
       return
     fi
   done
   echo "WARN: DMG mount still busy; forcing detach: $MOUNT_POINT" >&2
-  hdiutil detach "$MOUNT_POINT" -force || return 1
-  MOUNTED=0
+  for delay in 2 4 8; do
+    hdiutil detach "${DMG_DEVICE:-$MOUNT_POINT}" -force || hdiutil detach "$MOUNT_POINT" -force || true
+    if ! dmg_attached; then
+      MOUNTED=0
+      return
+    fi
+    sleep "$delay"
+  done
+  return 1
 }
 
 mkdir -p "$DMG_SOURCE" "$MOUNT_POINT"
@@ -171,8 +185,11 @@ hdiutil create \
   -format UDRW \
   "$DMG_RW_PATH"
 
-hdiutil attach "$DMG_RW_PATH" -mountpoint "$MOUNT_POINT" -nobrowse
+DMG_ATTACH_OUTPUT="$(hdiutil attach "$DMG_RW_PATH" -mountpoint "$MOUNT_POINT" -nobrowse)"
 MOUNTED=1
+echo "$DMG_ATTACH_OUTPUT"
+# Detach by device node survives the mount path disappearing under hdiutil.
+DMG_DEVICE="$(awk -v mount="$MOUNT_POINT" 'index($0, mount) && $1 ~ /^\/dev\/disk/ { print $1; exit }' <<<"$DMG_ATTACH_OUTPUT")"
 
 if [[ "${SKIP_DMG_STYLE:-0}" != "1" ]]; then
   mkdir -p "$MOUNT_POINT/.background"

test/scripts/create-dmg.test.ts

@@ -83,6 +83,8 @@ case "$command_name" in
       mkdir -p "$mountpoint"
       printf mounted > "$mountpoint/live-volume-file"
     fi
+    printf '%s' "$mountpoint" > "\${HDIUTIL_LOG}.attached"
+    printf '/dev/disk99\tGUID_partition_scheme\t\n/dev/disk99s1\tApple_HFS\t%s\n' "$mountpoint"
     ;;
   detach)
     if [[ "\${HDIUTIL_DETACH_FAIL:-0}" == "1" ]]; then
@@ -95,9 +97,16 @@ case "$command_name" in
     fi
     detach_attempts=$((detach_attempts + 1))
     printf '%s' "$detach_attempts" > "$detach_attempts_file"
+    vanish_at="\${HDIUTIL_DETACH_VANISH_AT:-0}"
+    if (( vanish_at > 0 && detach_attempts >= vanish_at )); then
+      rm -f "\${HDIUTIL_LOG}.attached"
+      echo "hdiutil: detach failed - No such file or directory" >&2
+      exit 1
+    fi
     if (( detach_attempts <= \${HDIUTIL_DETACH_FAIL_COUNT:-0} )); then
       exit 9
     fi
+    rm -f "\${HDIUTIL_LOG}.attached"
     ;;
   resize)
     if [[ "\${1:-}" == "-limits" ]]; then
@@ -132,6 +141,17 @@ esac
     writeFileSync(tool, `#!/bin/bash\nprintf '${command} %s\\n' "$*" >> "$HDIUTIL_LOG"\n`, "utf8");
     chmodSync(tool, 0o755);
   }
+  const mount = path.join(bin, "mount");
+  writeFileSync(
+    mount,
+    `#!/bin/bash
+echo '/dev/disk1s1 on / (apfs, sealed, local, read-only, journaled)'
+[[ -f "$HDIUTIL_LOG.attached" ]] && echo "/dev/disk99s1 on $(cat "$HDIUTIL_LOG.attached") (hfs, local, nobrowse)"
+exit 0
+`,
+    "utf8",
+  );
+  chmodSync(mount, 0o755);
   return {
     env: {
       HDIUTIL_LOG: hdiutilLog,
@@ -172,7 +192,10 @@ function expectPrivateDmgMount(log: string): string {
     log.matchAll(/^detach (.+?)(?: -(?:quiet|force))?$/gm),
     ([, target]) => target,
   );
-  expect(new Set(detachTargets)).toEqual(new Set([mountPoint]));
+  expect(detachTargets).toContain(mountPoint);
+  expect(detachTargets.filter((target) => target !== "/dev/disk99s1")).toEqual(
+    detachTargets.filter((target) => target === mountPoint),
+  );
   return mountPoint;
 }
 
@@ -396,15 +419,53 @@ describe.runIf(process.platform === "darwin")("create-dmg ownership boundaries",
     expect(result.stderr).toContain("Failed to detach DMG mount");
     expect(result.stderr).toContain("Preserving DMG temp root");
     const log = readFileSync(tools.hdiutilLog, "utf8");
+    const mountPoint = expectPrivateDmgMount(log);
     expect(log).not.toContain("resize");
     expect(log).not.toContain("convert");
-    // Ten packaging attempts plus the EXIT trap's last cleanup attempt.
-    expect(log.match(/^detach /gm)).toHaveLength(11);
-    const mountPoint = expectPrivateDmgMount(log);
+    // Nine polite attempts, three forced rounds by device then path, and the
+    // EXIT trap's last cleanup attempt.
+    expect(log.match(/^detach /gm)).toHaveLength(16);
+    expect(log.match(/^detach \/dev\/disk99s1 -force$/gm)).toHaveLength(4);
+    expect(log).toContain(`detach ${mountPoint} -force`);
     expect(readFileSync(path.join(mountPoint, "live-volume-file"), "utf8")).toBe("mounted");
     rmSync(path.dirname(mountPoint), { recursive: true, force: true });
   });
 
+  it.each([
+    { vanishAt: 5, detaches: 5, forced: false },
+    { vanishAt: 10, detaches: 11, forced: true },
+  ])(
+    "treats a busy volume that vanished at detach attempt $vanishAt as detached",
+    ({ vanishAt, detaches, forced }) => {
+      const app = makeValidApp();
+      const outputDir = mkdtempSync(path.join(tmpdir(), "openclaw-create-dmg-output-"));
+      tempDirs.push(outputDir);
+      const output = path.join(outputDir, "OpenClaw.dmg");
+      const tools = makeFakeDmgTools();
+
+      const result = runScript([app, output], {
+        ...tools.env,
+        HDIUTIL_DETACH_FAIL_COUNT: "9",
+        HDIUTIL_DETACH_VANISH_AT: String(vanishAt),
+      });
+
+      expect(result.status).toBe(0);
+      expect(readFileSync(output, "utf8")).toBe("converted");
+      expect(result.stderr).not.toContain("Preserving DMG temp root");
+      const log = readFileSync(tools.hdiutilLog, "utf8");
+      const mountPoint = expectPrivateDmgMount(log);
+      expect(existsSync(path.dirname(mountPoint))).toBe(false);
+      const detachLines = log.split("\n").filter((line) => line.startsWith("detach "));
+      expect(detachLines).toHaveLength(detaches);
+      // The forced round tries the device node first, then the mount path.
+      expect(detachLines.filter((line) => line.endsWith("-force"))).toEqual(
+        forced ? ["detach /dev/disk99s1 -force", `detach ${mountPoint} -force`] : [],
+      );
+      expect(log).toContain("resize");
+      expect(log).toContain("convert ");
+    },
+  );
+
   it.each([6, 9])("retries %i failed DMG detaches before finalizing the artifact", (failures) => {
     const app = makeValidApp();
     const outputDir = mkdtempSync(path.join(tmpdir(), "openclaw-create-dmg-output-"));