Fix streaming majors: PCM-only validation, stream-from-disk, ConcatStream offset, AsyncDisposable, HTTP cancellation, await ensureReady, seekBeyondBuffer offset-0 guard, negative WAV chunk guard

DeepDrftContent.Services/Audio/WavOffsetService.cs

@@ -8,13 +8,23 @@ namespace DeepDrftContent.Services.Audio;
 /// </summary>
 public class WavOffsetService
 {
+    /// <summary>
+    /// WAV audio format code for linear PCM. The pipeline (AudioProcessor,
+    /// WavOffsetService, and wavutils.ts) is PCM-only by design — IEEE Float
+    /// (format 3) and other formats are rejected at parse time so the
+    /// synthesized header here can safely assume PCM.
+    /// </summary>
+    public const short PcmFormat = 1;
+
     /// <summary>
     /// Creates a stream containing a synthesized WAV header followed by audio data from the specified offset.
+    /// The returned stream is composed of a small header buffer and a non-owning slice over the input
+    /// buffer — no copy of the audio payload is made.
     /// </summary>
     /// <param name="fullAudioBuffer">The complete WAV file buffer</param>
     /// <param name="byteOffset">Byte offset into the raw audio data (not including original header)</param>
-    /// <returns>MemoryStream with new WAV header + audio data from offset, or null if invalid</returns>
+    /// <returns>Stream with new WAV header + audio data from offset, or null if invalid</returns>
-    public MemoryStream? CreateOffsetStream(byte[] fullAudioBuffer, long byteOffset)
+    public Stream? CreateOffsetStream(byte[] fullAudioBuffer, long byteOffset)
     {
         var format = ParseWavHeader(fullAudioBuffer);
         if (format == null)
@@ -27,28 +37,44 @@ public class WavOffsetService
         // Align to block boundary for clean audio
         var alignedOffset = (byteOffset / format.BlockAlign) * format.BlockAlign;
 
-        // Calculate new data size
+        // Calculate new data size (long arithmetic — DataSize may be up to ~4 GB)
-        var newDataSize = format.DataSize - (int)alignedOffset;
+        var newDataSize = format.DataSize - alignedOffset;
         if (newDataSize <= 0)
             return null;
 
-        // Create new WAV header
+        // MemoryStream does not support offsets or lengths beyond int.MaxValue.
-        var newHeader = CreateWavHeader(format, newDataSize);
+        // RF64 (>2 GB audio segments) is not supported; reject before truncating.
-
-        // Calculate source position in original buffer
         var sourcePosition = format.HeaderSize + alignedOffset;
+        if (sourcePosition > int.MaxValue || newDataSize > int.MaxValue)
+            throw new NotSupportedException("Audio file segment exceeds 2 GB; RF64 not supported");
 
-        // Create result stream: new header + audio data from offset
+        var newDataSizeInt = (int)newDataSize;
-        var resultStream = new MemoryStream(44 + newDataSize);
+        var sourcePositionInt = (int)sourcePosition;
-        resultStream.Write(newHeader, 0, 44);
-        resultStream.Write(fullAudioBuffer, (int)sourcePosition, newDataSize);
-        resultStream.Position = 0;
 
-        return resultStream;
+        // Create new WAV header using the format reported by the parsed header.
+        // PCM is the only format we accept (see PcmFormat / ParseWavHeader), but
+        // threading format.AudioFormat through keeps the header self-consistent
+        // and prevents drift if the validation contract is ever relaxed.
+        var newHeader = CreateWavHeader(format, newDataSizeInt);
+
+        // Compose: 44-byte header followed by a non-copying slice of the audio payload.
+        // Wrapping the original buffer in a MemoryStream window avoids a 100MB+ copy
+        // that the previous MemoryStream(capacity).Write(...) implementation forced.
+        var headerStream = new MemoryStream(newHeader, writable: false);
+        var dataStream = new MemoryStream(
+            fullAudioBuffer,
+            sourcePositionInt,
+            newDataSizeInt,
+            writable: false,
+            publiclyVisible: false);
+
+        return new ConcatStream(headerStream, dataStream);
     }
 
     /// <summary>
     /// Parses the WAV header from a buffer to extract format information.
+    /// PCM-only — IEEE Float (format 3) and other non-PCM formats are rejected
+    /// so downstream synthesis can safely assume PCM sample encoding.
     /// </summary>
     public WavFormat? ParseWavHeader(byte[] buffer)
     {
@@ -70,8 +96,9 @@ public class WavOffsetService
         int bitsPerSample = 0;
         int byteRate = 0;
         int blockAlign = 0;
-        int dataSize = 0;
+        long dataSize = 0;
         int headerSize = 0;
+        short audioFormat = 0;
         bool foundFmt = false;
         bool foundData = false;
 
@@ -82,14 +109,20 @@ public class WavOffsetService
             var chunkId = Encoding.ASCII.GetString(buffer, chunkOffset, 4);
             var chunkSize = BitConverter.ToInt32(buffer, chunkOffset + 4);
 
+            if (chunkSize < 0)
+                return null;
+
             if (chunkId == "fmt ")
             {
                 if (chunkSize < 16)
                     return null;
 
-                var audioFormat = BitConverter.ToInt16(buffer, chunkOffset + 8);
+                audioFormat = BitConverter.ToInt16(buffer, chunkOffset + 8);
-                // Support PCM (1) and IEEE Float (3) formats
+                // PCM only. Float32 WAVs were previously accepted here but the synthesized
-                if (audioFormat != 1 && audioFormat != 3)
+                // header below is PCM-shaped — accepting Float would produce a corrupt file
+                // claiming PCM with Float-encoded samples. AudioProcessor also rejects
+                // non-PCM at upload time so this branch is defense in depth.
+                if (audioFormat != PcmFormat)
                     return null;
 
                 channels = BitConverter.ToInt16(buffer, chunkOffset + 10);
@@ -106,7 +139,9 @@ public class WavOffsetService
             }
             else if (chunkId == "data")
             {
-                dataSize = chunkSize;
+                // WAV stores DataSize as a 32-bit unsigned int. Read as uint to preserve
+                // values above int.MaxValue (files between 2–4 GB), then widen to long.
+                dataSize = (long)BitConverter.ToUInt32(buffer, chunkOffset + 4);
                 headerSize = chunkOffset + 8; // Audio data starts after 'data' + size (8 bytes)
                 foundData = true;
             }
@@ -124,6 +159,7 @@ public class WavOffsetService
             return null;
 
         return new WavFormat(
+            AudioFormat: audioFormat,
             SampleRate: sampleRate,
             Channels: channels,
             BitsPerSample: bitsPerSample,
@@ -135,7 +171,9 @@ public class WavOffsetService
     }
 
     /// <summary>
-    /// Creates a standard 44-byte PCM WAV header.
+    /// Creates a standard 44-byte WAV header. The audio format code is taken from
+    /// <paramref name="format"/> rather than hardcoded so the synthesized header matches
+    /// what was parsed (today always <see cref="PcmFormat"/>; see ParseWavHeader).
     /// </summary>
     public byte[] CreateWavHeader(WavFormat format, int dataSize)
     {
@@ -150,7 +188,7 @@ public class WavOffsetService
         // fmt chunk
         header[12] = (byte)'f'; header[13] = (byte)'m'; header[14] = (byte)'t'; header[15] = (byte)' ';
         BitConverter.GetBytes(16).CopyTo(header, 16); // fmt chunk size
-        BitConverter.GetBytes((short)1).CopyTo(header, 20); // Audio format (PCM)
+        BitConverter.GetBytes(format.AudioFormat).CopyTo(header, 20); // Audio format (from parsed header)
         BitConverter.GetBytes((short)format.Channels).CopyTo(header, 22);
         BitConverter.GetBytes(format.SampleRate).CopyTo(header, 24);
         BitConverter.GetBytes(format.ByteRate).CopyTo(header, 28);
@@ -168,12 +206,110 @@ public class WavOffsetService
 /// <summary>
 /// WAV format information extracted from header.
 /// </summary>
+/// <param name="AudioFormat">WAV fmt-chunk audio format code (1 = PCM; the only value accepted today).</param>
 public record WavFormat(
+    short AudioFormat,
     int SampleRate,
     int Channels,
     int BitsPerSample,
     int ByteRate,
     int BlockAlign,
-    int DataSize,
+    long DataSize,
     int HeaderSize
 );
+
+/// <summary>
+/// Forward-only read stream over two underlying streams concatenated end-to-end.
+/// Lets us serve "[synthesized header][slice of original buffer]" without
+/// allocating a single contiguous buffer for the combined payload.
+/// </summary>
+internal sealed class ConcatStream : Stream
+{
+    private readonly Stream _first;
+    private readonly Stream _second;
+    private readonly long _length;
+    private long _position;
+
+    public ConcatStream(Stream first, Stream second)
+    {
+        _first = first;
+        _second = second;
+        _length = first.Length + second.Length;
+    }
+
+    public override bool CanRead => true;
+    public override bool CanSeek => false;
+    public override bool CanWrite => false;
+    public override long Length => _length;
+
+    public override long Position
+    {
+        get => _position;
+        set => throw new NotSupportedException();
+    }
+
+    public override int Read(byte[] buffer, int offset, int count)
+    {
+        var total = 0;
+
+        // Loop over _first until it returns 0 (exhausted) or the caller's buffer
+        // is full. Stream.Read is not required to fill the buffer in one call even
+        // when data is available (e.g. a future non-MemoryStream _first), so we must
+        // keep pulling until we get 0 before advancing to _second.
+        while (count > 0 && _position < _first.Length)
+        {
+            var read = _first.Read(buffer, offset, count);
+            if (read == 0) break;
+            total += read;
+            _position += read;
+            offset += read;
+            count -= read;
+        }
+
+        if (count > 0)
+        {
+            var read = _second.Read(buffer, offset, count);
+            total += read;
+            _position += read;
+        }
+        return total;
+    }
+
+    public override async ValueTask<int> ReadAsync(Memory<byte> buffer, CancellationToken cancellationToken = default)
+    {
+        var total = 0;
+
+        // Same loop contract as Read() — exhaust _first before reading _second.
+        while (!buffer.IsEmpty && _position < _first.Length)
+        {
+            var read = await _first.ReadAsync(buffer, cancellationToken);
+            if (read == 0) break;
+            total += read;
+            _position += read;
+            buffer = buffer[read..];
+        }
+
+        if (!buffer.IsEmpty)
+        {
+            var read = await _second.ReadAsync(buffer, cancellationToken);
+            total += read;
+            _position += read;
+        }
+        return total;
+    }
+
+    public override void Flush() { }
+    public override long Seek(long offset, SeekOrigin origin) => throw new NotSupportedException();
+    public override void SetLength(long value) => throw new NotSupportedException();
+    public override void Write(byte[] buffer, int offset, int count) => throw new NotSupportedException();
+
+    protected override void Dispose(bool disposing)
+    {
+        if (disposing)
+        {
+            _first.Dispose();
+            _second.Dispose();
+        }
+        base.Dispose(disposing);
+    }
+}

DeepDrftContent.Services/FileDatabase/Services/MediaVault.cs

@@ -84,6 +84,53 @@ public abstract class MediaVault : VaultIndexDirectory
         return (T)result;
     }
 
+    /// <summary>
+    /// Opens a read-only stream over an entry's backing file plus its metadata
+    /// (extension/MIME), without buffering the file into memory.
+    /// Returns null if the entry is unknown or the backing file is missing.
+    ///
+    /// Use this when the caller will forward bytes to a network response — the
+    /// existing <see cref="GetEntryAsync{T}"/> allocates a full <c>byte[]</c>
+    /// and pushes large WAVs onto the LOH for every request.
+    ///
+    /// The caller owns the returned stream and must dispose it. Error-handling
+    /// follows the same swallow-and-return-null contract as the rest of the
+    /// FileDatabase API; the caller checks for null.
+    /// </summary>
+    public async Task<MediaStream?> GetEntryStreamAsync(string entryId)
+    {
+        try
+        {
+            if (!await HasIndexEntry(entryId))
+                return null;
+
+            var metaData = await GetEntryMetadata(entryId);
+            if (metaData == null)
+                return null;
+
+            var mediaPath = GetMediaPathFromEntryKey(metaData.MediaKey, metaData.Extension);
+            if (!FileUtils.FileExists(mediaPath))
+                return null;
+
+            // Async-capable, sequential-scan FileStream — the response writer will pull
+            // bytes in order. bufferSize matches FileUtils.FetchFileAsync (64 KB).
+            var stream = new FileStream(
+                mediaPath,
+                FileMode.Open,
+                FileAccess.Read,
+                FileShare.Read,
+                bufferSize: 64 * 1024,
+                useAsync: true);
+
+            return new MediaStream(stream, metaData.Extension);
+        }
+        catch
+        {
+            // Match FileDatabase error-swallow contract.
+            return null;
+        }
+    }
+
     /// <summary>
     /// Extracts buffer and extension from a media binary
     /// </summary>
@@ -141,3 +188,22 @@ public class AudioVault : MediaVault
         return null;
     }
 }
+
+/// <summary>
+/// An open read-only stream over a vault entry plus the extension needed to
+/// resolve its MIME type. Caller owns the stream and must dispose it.
+/// </summary>
+public sealed class MediaStream : IDisposable, IAsyncDisposable
+{
+    public Stream Stream { get; }
+    public string Extension { get; }
+
+    public MediaStream(Stream stream, string extension)
+    {
+        Stream = stream;
+        Extension = extension;
+    }
+
+    public void Dispose() => Stream.Dispose();
+    public ValueTask DisposeAsync() => Stream.DisposeAsync();
+}

DeepDrftContent/Controllers/TrackController.cs

@@ -1,6 +1,7 @@
-using DeepDrftContent.Services.Audio;
+using DeepDrftContent.Services.Audio;
 using DeepDrftContent.Services.Constants;
 using DeepDrftContent.Services.FileDatabase.Models;
+using DeepDrftContent.Services.FileDatabase.Services;
 using DeepDrftContent.Middleware;
 using Microsoft.AspNetCore.Mvc;
 
@@ -31,6 +32,57 @@ public class TrackController : ControllerBase
 
         try
         {
+            // No-offset path: stream the file straight from disk so a 100 MB WAV does not
+            // force a 100 MB LOH allocation per request. The offset path still loads
+            // the full buffer because WavOffsetService block-aligns and reslices into
+            // a composite stream over the in-memory buffer.
+            if (offset == 0)
+            {
+                var vault = _fileDatabase.GetVault(VaultConstants.Tracks);
+                if (vault == null)
+                {
+                    _logger.LogWarning("Tracks vault not found");
+                    return NotFound();
+                }
+
+                var mediaStream = await vault.GetEntryStreamAsync(trackId);
+                if (mediaStream == null)
+                {
+                    _logger.LogWarning("Track not found: {TrackId}", trackId);
+                    return NotFound();
+                }
+
+                // Resolve MIME and log before handing the stream to File().
+                // If anything here throws, the finally block disposes the wrapper
+                // (and its inner FileStream) so neither leaks. On the success path
+                // File() takes ownership of the inner stream; ASP.NET Core disposes
+                // it after the response body is sent. The wrapper is a thin struct
+                // with no extra resources, so disposing it after extracting the
+                // inner stream is a no-op — we only call Dispose() in the catch path.
+                string streamMimeType;
+                long streamLength;
+                Stream innerStream;
+                try
+                {
+                    streamMimeType = MimeTypeExtensions.GetMimeType(mediaStream.Extension);
+                    streamLength = mediaStream.Stream.Length;
+                    innerStream = mediaStream.Stream;
+                }
+                catch
+                {
+                    await mediaStream.DisposeAsync();
+                    throw;
+                }
+
+                _logger.LogInformation(
+                    "Streaming track from disk: {TrackId}, Size: {Size} bytes",
+                    trackId, streamLength);
+                // enableRangeProcessing: false — seek is served by WavOffsetService, not Range.
+                return File(innerStream, streamMimeType, enableRangeProcessing: false);
+            }
+
+            // Offset path: buffer the file (current behaviour) and synthesise a
+            // header-prefixed slice via WavOffsetService.
             var file = await _fileDatabase.LoadResourceAsync<AudioBinary>(VaultConstants.Tracks, trackId);
             if (file == null)
             {
@@ -40,14 +92,6 @@ public class TrackController : ControllerBase
 
             var mimeType = MimeTypeExtensions.GetMimeType(file.Extension);
 
-            // If no offset, return the full file
-            if (offset == 0)
-            {
-                _logger.LogInformation("Successfully retrieved track: {TrackId}, Size: {Size} bytes", trackId, file.Buffer.Length);
-                return File(file.Buffer, mimeType);
-            }
-
-            // Create offset stream with synthesized header
             var offsetStream = _wavOffsetService.CreateOffsetStream(file.Buffer, offset);
             if (offsetStream == null)
             {

DeepDrftWeb.Client/Clients/TrackMediaClient.cs

@@ -29,7 +29,16 @@ public class TrackMediaClient
         _http = httpClientFactory.CreateClient("DeepDrft.Content");
     }
 
-    public async Task<ApiResult<TrackMediaResponse>> GetTrackMedia(string trackId, long byteOffset = 0)
+    /// <summary>
+    /// Fetches the WAV stream for a track, optionally starting from a byte offset.
+    /// The cancellation token is forwarded to <see cref="HttpClient.GetAsync"/> so a
+    /// navigation or seek-replacement aborts the in-flight server connection rather
+    /// than leaving the server draining bytes into a dead socket.
+    /// </summary>
+    public async Task<ApiResult<TrackMediaResponse>> GetTrackMedia(
+        string trackId,
+        long byteOffset = 0,
+        CancellationToken cancellationToken = default)
     {
         try
         {
@@ -39,11 +48,11 @@ public class TrackMediaClient
                 : $"api/track/{trackId}";
 
             // Use HttpCompletionOption.ResponseHeadersRead to get stream immediately
-            var response = await _http.GetAsync(url, HttpCompletionOption.ResponseHeadersRead);
+            var response = await _http.GetAsync(url, HttpCompletionOption.ResponseHeadersRead, cancellationToken);
             response.EnsureSuccessStatusCode();
 
             var contentLength = response.Content.Headers.ContentLength ?? 0;
-            var stream = await response.Content.ReadAsStreamAsync();
+            var stream = await response.Content.ReadAsStreamAsync(cancellationToken);
 
             return ApiResult<TrackMediaResponse>.CreatePassResult(new TrackMediaResponse(stream, contentLength));
         }

DeepDrftWeb.Client/Controls/AudioPlayerProvider.razor.cs

@@ -1,11 +1,11 @@
-using DeepDrftWeb.Client.Services;
+using DeepDrftWeb.Client.Services;
 using DeepDrftWeb.Client.Clients;
 using Microsoft.AspNetCore.Components;
 using Microsoft.Extensions.Logging;
 
 namespace DeepDrftWeb.Client.Controls;
 
-public partial class AudioPlayerProvider : ComponentBase
+public partial class AudioPlayerProvider : ComponentBase, IAsyncDisposable
 {
     [Inject] public required AudioInteropService AudioInterop { get; set; }
     [Inject] public required TrackMediaClient TrackMediaClient { get; set; }
@@ -35,4 +35,18 @@ public partial class AudioPlayerProvider : ComponentBase
             StateHasChanged();
         }
     }
+
+    /// <summary>
+    /// Dispose the player on unmount so the JS setInterval driving progress
+    /// callbacks no longer holds a DotNetObjectReference into a destroyed
+    /// component (otherwise it throws every 100ms after navigation away).
+    /// </summary>
+    public async ValueTask DisposeAsync()
+    {
+        if (_audioPlayerService != null)
+        {
+            await _audioPlayerService.DisposeAsync();
+            _audioPlayerService = null;
+        }
+    }
 }

DeepDrftWeb.Client/Services/AudioPlayerService.cs

@@ -392,7 +392,7 @@ public abstract class AudioPlayerService : IPlayerService, IAsyncDisposable
             await OnTrackSelected.Value.InvokeAsync();
     }
 
-    public async ValueTask DisposeAsync()
+    public virtual async ValueTask DisposeAsync()
     {
         if (IsInitialized)
         {

DeepDrftWeb.Client/Services/StreamingAudioPlayerService.cs

@@ -90,7 +90,12 @@ public class StreamingAudioPlayerService : AudioPlayerService, IStreamingPlayerS
 
             await NotifyStateChanged();
 
-            var mediaResult = await _trackMediaClient.GetTrackMedia(track.EntryKey);
+            // Pass the streaming token to the HTTP layer so a navigation/track switch
+            // aborts the server connection instead of leaving it draining bytes.
+            var mediaResult = await _trackMediaClient.GetTrackMedia(
+                track.EntryKey,
+                byteOffset: 0,
+                cancellationToken: _streamingCancellation.Token);
             if (!mediaResult.Success)
             {
                 var technicalError = mediaResult.GetMessage();
@@ -346,7 +351,10 @@ public class StreamingAudioPlayerService : AudioPlayerService, IStreamingPlayerS
             await NotifyStateChanged();
 
             // Request new stream from offset
-            var mediaResult = await _trackMediaClient.GetTrackMedia(_currentTrackId, byteOffset);
+            var mediaResult = await _trackMediaClient.GetTrackMedia(
+                _currentTrackId,
+                byteOffset,
+                cancellationToken: _streamingCancellation.Token);
             if (!mediaResult.Success || mediaResult.Value == null)
             {
                 var technicalError = mediaResult.GetMessage() ?? "Failed to load audio from position";
@@ -485,6 +493,25 @@ public class StreamingAudioPlayerService : AudioPlayerService, IStreamingPlayerS
         }
     }
 
+    /// <summary>
+    /// On component unmount we must cancel the in-flight streaming loop and tear
+    /// down JS callbacks before the JS side's setInterval fires again with a
+    /// stale DotNetObjectReference. ResetToIdle covers cancellation + JS stop
+    /// + state reset; the base then disposes the JS player and its callbacks.
+    /// </summary>
+    public override async ValueTask DisposeAsync()
+    {
+        try
+        {
+            await ResetToIdle();
+        }
+        catch
+        {
+            // Disposal must not throw; any failure here is best-effort cleanup.
+        }
+        await base.DisposeAsync();
+    }
+
     private void AdaptBufferSize(int bytesRead, long readTimeMs)
     {
         // Adaptive buffer sizing based on network performance

DeepDrftWeb/Interop/audio/AudioPlayer.ts

@@ -175,13 +175,21 @@ export class AudioPlayer {
         }
     }
 
-    startStreamingPlayback(): AudioResult {
+    async startStreamingPlayback(): Promise<AudioResult> {
         if (!this.scheduler.hasBuffers()) {
             return { success: false, error: 'No buffers available' };
         }
 
         try {
             console.log('\n=== Starting streaming playback ===');
+
+            // A backgrounded tab leaves AudioContext suspended. createBufferSource/start
+            // against a suspended context produces no audio without throwing — the same
+            // failure mode that was fixed for play() (resume path). Awaiting ensureReady()
+            // here guarantees the context is running before playFromPosition schedules
+            // any AudioBufferSourceNodes.
+            await this.contextManager.ensureReady();
+
             this.streamingStarted = true;
             this.isPlaying = true;
             this.isPaused = false;
@@ -199,7 +207,7 @@ export class AudioPlayer {
 
     // ==================== Playback Control ====================
 
-    play(): AudioResult {
+    async play(): Promise<AudioResult> {
         if (!this.isStreamingMode) {
             return { success: false, error: 'Not in streaming mode' };
         }
@@ -215,7 +223,11 @@ export class AudioPlayer {
         }
 
         try {
-            this.contextManager.ensureReady();
+            // Must await: a backgrounded tab leaves AudioContext suspended, and
+            // createBufferSource/source.start against a suspended context produces
+            // no audio without throwing. Firing ensureReady() without await meant
+            // play() returned success but the user heard nothing.
+            await this.contextManager.ensureReady();
 
             this.isPlaying = true;
             this.isPaused = false;
@@ -313,7 +325,9 @@ export class AudioPlayer {
     private seekBeyondBuffer(position: number): AudioResult {
         try {
             const byteOffset = this.streamDecoder.calculateByteOffset(position);
-            if (byteOffset <= 0) {
+            // 0 is a valid offset (seek to start of audio data). Only a negative result
+            // indicates calculation failure — typically a missing/unparsed WAV header.
+            if (byteOffset < 0) {
                 return { success: false, error: 'Cannot calculate byte offset' };
             }
 

DeepDrftWeb/Interop/audio/PlaybackScheduler.ts

@@ -110,7 +110,15 @@ export class PlaybackScheduler {
         }
 
         if (startBufferIndex >= this.buffers.length) {
-            console.log('Position beyond available buffers');
+            // Position landed at or past the end of all buffers. Previously this
+            // returned silently, leaving the player stuck "playing" with no source
+            // scheduled — a pause near the end followed by play never recovered.
+            // Treat this as end-of-track so listeners (UI / end callback) fire.
+            console.log('Position at/beyond available buffers — ending playback');
+            this.isActive_ = false;
+            this.playbackAnchorTime = 0;
+            this.playbackAnchorPosition = 0;
+            this.onPlaybackEnded?.();
             return;
         }
 

DeepDrftWeb/Interop/audio/StreamDecoder.ts

@@ -12,6 +12,36 @@ export interface DecodedChunkResult {
     duration: number;
 }
 
+/**
+ * Thrown when decodeAudioData exceeds the per-segment deadline. Distinct from
+ * DecodeError so callers (and operators reading logs) can tell a slow/throttled
+ * decoder from corrupt audio data — the previous "Decode timeout" string error
+ * was indistinguishable from any other Error and was silently swallowed.
+ */
+export class DecodeTimeoutError extends Error {
+    constructor(public readonly segmentOffset: number, public readonly byteCount: number) {
+        super(`Decode timeout at offset ${segmentOffset} (${byteCount} bytes)`);
+        this.name = 'DecodeTimeoutError';
+    }
+}
+
+/**
+ * Thrown when decodeAudioData rejects for non-timeout reasons (corrupt header,
+ * unsupported format, etc.). Carries the segment offset so callers can log
+ * which part of the stream failed.
+ */
+export class DecodeError extends Error {
+    constructor(
+        message: string,
+        public readonly segmentOffset: number,
+        public readonly byteCount: number,
+        public readonly cause?: Error
+    ) {
+        super(message);
+        this.name = 'DecodeError';
+    }
+}
+
 export class StreamDecoder {
     // Upper bound on pre-header accumulation. 256 KB is far beyond any sane WAV
     // header (including extended LIST/INFO/JUNK chunks). If we have accumulated
@@ -173,7 +203,15 @@ export class StreamDecoder {
     }
 
     /**
-     * Try to decode the next segment of audio
+     * Try to decode the next segment of audio.
+     *
+     * Failure modes:
+     *  - Decode timeout: retry once, then surface as DecodeTimeoutError (typed).
+     *  - Other decode error (corrupt data, format mismatch): surface as DecodeError.
+     * Both are thrown rather than silently swallowed — callers (processChunk /
+     * markStreamComplete) decide whether to abort the stream or skip the segment.
+     * processedBytes is only advanced on success so a thrown failure does not
+     * silently consume the failed segment.
      */
     private async tryDecodeNextSegment(): Promise<DecodedChunkResult | null> {
         if (!this.wavHeader) return null;
@@ -199,15 +237,63 @@ export class StreamDecoder {
         const wavFile = this.createWavFile(rawSegment);
 
         try {
-            const buffer = await this.decodeWithTimeout(wavFile);
+            const buffer = await this.decodeWithRetry(wavFile, segmentOffset, alignedSize);
-            // Advance only after a successful decode so that a timeout or decode
+            // Advance only after a successful decode so a thrown timeout/decode
-            // failure does not permanently skip the segment.
+            // failure does not silently drop the segment.
             this.processedBytes += alignedSize;
             console.log(`✓ Decoded: ${buffer.duration.toFixed(3)}s, ${buffer.numberOfChannels}ch`);
             return { buffer, duration: buffer.duration };
         } catch (error) {
-            console.error(`Failed to decode segment at offset ${segmentOffset}:`, error);
+            // Re-throw typed errors so the outer drain loop in processChunk /
-            return null;
+            // markStreamComplete sees the real failure instead of an empty array.
+            // The previous silent return hid timeouts entirely.
+            if (error instanceof DecodeTimeoutError || error instanceof DecodeError) {
+                throw error;
+            }
+            // Unknown synchronous failure during decode — wrap and surface.
+            throw new DecodeError(
+                `Decode failed at offset ${segmentOffset} (${alignedSize} bytes): ${(error as Error).message}`,
+                segmentOffset,
+                alignedSize,
+                error as Error);
+        }
+    }
+
+    /**
+     * Decode with a single retry on timeout. Web Audio's decodeAudioData is
+     * occasionally flaky under tab throttling; a retry costs little and recovers
+     * the common transient case without dropping the segment.
+     */
+    private async decodeWithRetry(
+        wavData: Uint8Array,
+        segmentOffset: number,
+        alignedSize: number): Promise<AudioBuffer> {
+        try {
+            return await this.decodeWithTimeout(wavData);
+        } catch (error) {
+            if (!(error instanceof DecodeTimeoutError)) {
+                throw new DecodeError(
+                    `Decode failed at offset ${segmentOffset} (${alignedSize} bytes): ${(error as Error).message}`,
+                    segmentOffset,
+                    alignedSize,
+                    error as Error);
+            }
+            console.warn(
+                `Decode timeout at offset ${segmentOffset} (${alignedSize} bytes) — retrying once`);
+            try {
+                return await this.decodeWithTimeout(wavData);
+            } catch (retryError) {
+                if (retryError instanceof DecodeTimeoutError) {
+                    console.error(
+                        `Decode timeout after retry at offset ${segmentOffset} (${alignedSize} bytes)`);
+                    throw new DecodeTimeoutError(segmentOffset, alignedSize);
+                }
+                throw new DecodeError(
+                    `Decode failed on retry at offset ${segmentOffset} (${alignedSize} bytes): ${(retryError as Error).message}`,
+                    segmentOffset,
+                    alignedSize,
+                    retryError as Error);
+            }
         }
     }
 
@@ -257,18 +343,25 @@ export class StreamDecoder {
     }
 
     /**
-     * Decode with timeout to prevent hanging
+     * Decode with timeout to prevent hanging. Throws DecodeTimeoutError if the
+     * deadline expires so callers can distinguish timeout from corrupt-data
+     * failures (decodeAudioData throws DOMException for the latter).
      */
     private async decodeWithTimeout(wavData: Uint8Array, timeoutMs: number = 5000): Promise<AudioBuffer> {
         const buffer = new ArrayBuffer(wavData.length);
         new Uint8Array(buffer).set(wavData);
 
         const decodePromise = this.contextManager.decodeAudioData(buffer);
+        let timer: ReturnType<typeof setTimeout> | null = null;
         const timeoutPromise = new Promise<never>((_, reject) => {
-            setTimeout(() => reject(new Error('Decode timeout')), timeoutMs);
+            timer = setTimeout(() => reject(new DecodeTimeoutError(-1, wavData.length)), timeoutMs);
         });
 
-        return Promise.race([decodePromise, timeoutPromise]);
+        try {
+            return await Promise.race([decodePromise, timeoutPromise]);
+        } finally {
+            if (timer !== null) clearTimeout(timer);
+        }
     }
 
     /**

DeepDrftWeb/Interop/audio/index.ts

@@ -39,7 +39,7 @@ const DeepDrftAudio = {
         return player.processStreamingChunk(chunk);
     },
 
-    startStreamingPlayback: (playerId: string): AudioResult => {
+    startStreamingPlayback: async (playerId: string): Promise<AudioResult> => {
         const player = audioPlayers.get(playerId);
         if (!player) return { success: false, error: 'Player not found' };
         return player.startStreamingPlayback();
@@ -57,7 +57,7 @@ const DeepDrftAudio = {
         return player.ensureAudioContextReady();
     },
 
-    play: (playerId: string): AudioResult => {
+    play: async (playerId: string): Promise<AudioResult> => {
         const player = audioPlayers.get(playerId);
         if (!player) return { success: false, error: 'Player not found' };
         return player.play();

DeepDrftWeb/Interop/wavutils.ts

@@ -51,9 +51,11 @@ class WavUtils {
                 if (chunkSize < 16) return null;
 
                 const audioFormat = view.getUint16(chunkOffset + 8, true);
-                // Support PCM (1) and IEEE Float (3) formats
+                // PCM only. The server's WavOffsetService synthesises PCM-shaped headers,
-                if (audioFormat !== 1 && audioFormat !== 3) {
+                // and AudioProcessor rejects non-PCM at upload — accepting Float here would
-                    console.warn(`Unsupported audio format: ${audioFormat} (only PCM=1 and IEEE Float=3 supported)`);
+                // hand the decoder a header/payload mismatch that surfaces as garbled audio.
+                if (audioFormat !== 1) {
+                    console.warn(`Unsupported audio format: ${audioFormat} (only PCM=1 supported)`);
                     return null;
                 }