Fix iOS device test random launch failures with improved retry logic and timeouts (#30796)

* Initial plan

* Fix iOS device test random launch failures with improved retry logic and timeouts

Co-authored-by: rmarinho <[email protected]>

* Apply suggestion from @Copilot

Co-authored-by: Copilot <[email protected]>

* Fix Cake script compilation error: Replace Task.Delay with Thread.Sleep

Co-authored-by: rmarinho <[email protected]>

---------

Co-authored-by: copilot-swe-agent[bot] <[email protected]>
Co-authored-by: rmarinho <[email protected]>
Co-authored-by: Rui Marinho <[email protected]>
Co-authored-by: Copilot <[email protected]>

Author: 3 people

eng/devices/devices-shared.cake

@@ -299,6 +299,13 @@ void RunMacAndiOSTests(
 				catch (Exception ex)
 				{
 					Information($"Test attempt {i} failed: {ex.Message}");
+					bool isLaunchFailure = IsSimulatorLaunchFailure(ex);
+					
+					if (isLaunchFailure)
+					{
+						Information("Detected simulator launch failure (exit code 4). This may be a transient issue.");
+					}
+					
 					if (i == 1)
                     {
 						throw;
@@ -313,6 +320,13 @@ void RunMacAndiOSTests(
                         {
                             DeleteFile(logFile);
                         }
+                        
+                        // For launch failures, add a small delay to let the simulator settle
+                        if (isLaunchFailure)
+                        {
+                            Information("Adding delay before retry due to launch failure...");
+                            System.Threading.Thread.Sleep(5000); // 5 second delay
+                        }
                     }
 				}
 			}
@@ -376,3 +390,14 @@ string SanitizeTestResultsFilename(string input)
 
     return resultFilename;
 }
+
+bool IsSimulatorLaunchFailure(Exception ex)
+{
+    // Check if the exception message contains indicators of simulator launch failures
+    var message = ex.Message;
+    return message.Contains("simctl returned exit code 4") || 
+           message.Contains("HE0042") ||
+           message.Contains("Could not launch the app") ||
+           message.Contains("FBSOpenApplicationServiceErrorDomain") ||
+           message.Contains("Simulator device failed to launch");
+}

eng/devices/ios.cake

@@ -171,9 +171,11 @@ void ExecuteTests(string project, string device, string resultsDir, string confi
 		xcode_args = $"--xcode=\"{XCODE_PATH}\" ";
 	}
 
-	Information($"Testing App: {testApp}");
-
+	// Use longer launch timeout for CI builds to handle problematic conditions
+	var launchTimeout = IsCIBuild() ? "00:10:00" : "00:06:00";
+	Information($"Using launch timeout: {launchTimeout} (CI: {IsCIBuild()})");
 
+	Information($"Testing App: {testApp}");
 
 	RunMacAndiOSTests(project, device, resultsDir, config, tfm, rid, toolPath, projectPath, (category) =>
 	{
@@ -188,7 +190,7 @@ void ExecuteTests(string project, string device, string resultsDir, string confi
 					$"--targets=\"{device}\" " +
 					$"--output-directory=\"{resultsDir}\" " +
 					$"--timeout=01:15:00 " +
-					$"--launch-timeout=00:06:00 " +
+					$"--launch-timeout={launchTimeout} " +
 					xcode_args +
 					$"--verbosity=\"Debug\" " +
 					$"--set-env=\"TestFilter={category}\" ");

eng/pipelines/common/device-tests-steps.yml

@@ -140,7 +140,7 @@ steps:
   displayName: Execute Test Run
   workingDirectory: ${{ parameters.checkoutDirectory }}
   condition: and(succeeded(), ne('${{ parameters.buildType }}', 'buildOnly'))
-  ${{ if or(eq(parameters.buildType, 'windows'), eq(parameters.platform, 'android')) }}:
+  ${{ if or(eq(parameters.buildType, 'windows'), eq(parameters.platform, 'android'), eq(parameters.platform, 'ios')) }}:
     retryCountOnTaskFailure: 1
 
 ##################################################

src/Templates/src/cgmanifest.json

@@ -105,7 +105,7 @@
         "type": "nuget",
         "nuget": {
           "name": "Microsoft.WindowsAppSDK",
-          "version": "1.7.250513003"
+          "version": "1.7.250606001"
         }
       }
     },