[build-tools] Fix ai-*.json is not guarenteed in Maestro 2.5

[hSATAC]

Why

Maestro 2.5.0 (released 2026-04-27) changed TestDebugReporter.saveSuggestions to early-return when a flow has no AI screen outputs. As a result, ai-${flow_name}.json is now only emitted for flows using AI commands (e.g. assertWithAI).

Two callers in @expo/build-tools relied on ai-*.json for the flow_name → flow_file_path mapping:

• Smart retry (parseFailedFlowsFromJUnit): lookup misses every time on 2.5.0+, so smart retry silently degrades to dumb retry — a functional regression of [build-tools] Add eas/run_maestro_tests step with smart retry #3635 against the latest Maestro.
• Test result reporting (parseMaestroResults): the path on uploaded testCaseResults falls back to flow name. Cosmetic-only — path is read in the workflow detail UI as a hover tooltip.

Linear: ENG-19927. Stacked on #3635.

How

Replace the ai-*.json walk with a self-built flow_name → flow_file_path map (buildFlowNameToPathMap). The helper walks the user's flow_paths input, parses each flow YAML's top-level name (or falls back to file basename without extension), and produces a name → path map. Both parseFailedFlowsFromJUnit and parseMaestroResults consume it.

• Map values are project-root-relative paths (preserving today's GraphQL path semantics).
• Duplicate flow names produce a warning and disable smart retry for that run; consumers receive null and fall back to the previous degraded behavior.
• Adds a new optional flow_paths input to eas/report_maestro_test_results. Universe-side wiring (passing job.params.flow_path into this input) is a separate PR.

Behavior change for eas/report_maestro_test_results: single-attempt retryCount is no longer derived from ai-*.json occurrence count, falls back to 0. Production impact: zero — no readers of retryCount, and the only caller of the single-attempt branch (the bash step) is retired by #3641.

Backward compatibility during deployment: between this PR landing and the universe wiring landing, old job specs (without flow_paths on the report step) run against the new code. The step silently falls back to null map → flow-name-as-path, no warnings.

Test Plan

• 27 new unit tests in maestroFlowDiscovery.test.ts covering: top-level name, basename fallback, malformed YAML, missing files, leading --- document marker, directory walks, symlink cycles (real fs), workspace config.yaml skip, duplicate-name handling, same-file dedup, absolute paths.
• All existing tests updated (88 passing across maestroResultParser.test.ts, reportMaestroTestResults.test.ts, runMaestroTests.test.ts).
• Local end-to-end verification on Maestro 2.5.0 against the playground (intentionally flaky flows):
  • --shard-split=2: failed flows from attempt 1 retried with project-relative paths; sharding adjusted to the retried subset.
  • No sharding: failed flows retried in attempt 2; flaky failures recovered (final PASS).

[linear]

ENG-19927 Only retry failed Maestro flows in reuse_devices mode

[hSATAC]

• [build-tools] Fix ai-*.json is not guarenteed in Maestro 2.5 #3639 👈 (View in Graphite)
• [build-tools] Add eas/run_maestro_tests step with smart retry #3635
• [build-tools] Port Maestro Tests bash step to TypeScript #3641
• main

This stack of pull requests is managed by Graphite. Learn more about stacking.

[github-actions]

Subscribed to pull request

File Patterns	Mentions
**/*	@douglowder

Generated by CodeMention

[codecov]

Codecov Report

❌ Patch coverage is 91.09589% with 13 lines in your changes missing coverage. Please review.
✅ Project coverage is 56.63%. Comparing base (4da5b40) to head (0755678).
⚠️ Report is 1 commits behind head on main.

Files with missing lines	Patch %	Lines
...-tools/src/steps/functions/maestroFlowDiscovery.ts	89.82%	11 Missing ⚠️
...ls/src/steps/functions/reportMaestroTestResults.ts	83.34%	2 Missing ⚠️

Additional details and impacted files

@@            Coverage Diff             @@
##             main    #3639      +/-   ##
==========================================
+ Coverage   56.62%   56.63%   +0.01%     
==========================================
  Files         886      888       +2     
  Lines       38331    38416      +85     
  Branches     7977     8009      +32     
==========================================
+ Hits        21703    21754      +51     
- Misses      16530    16564      +34     
  Partials       98       98              

☔ View full report in Codecov by Sentry.
📢 Have feedback on the report? Share it here.

🚀 New features to boost your workflow:

• ❄️ Test Analytics: Detect flaky tests, report on failures, and find test suite problems.
• 📦 JS Bundle Analysis: Save yourself from yourself by tracking and limiting bundle sizes in JS merges.

[sjchmiela]

a bit hard to wrap one's head around everything that's needed, but i trust you and your testing. i wish the junit output had everything we need. maybe we can submit a pull request to maestro?

[sjchmiela]

nit: we can do manual === || === check which i think is slightly easier

[hSATAC]

I am leaning to keep this as this is simple enough and also handles uppercase/lowercase.

[sjchmiela]

what is the missing piece of information from maestro that could let us not have this? maybe they'd consider adding filepath to junit test results? i think this would fix the problem for us too?

[hSATAC]

Yeah that's actually a great idea.

[github-actions]

⏩ The changelog entry check has been skipped since the "no changelog" label is present.