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feat(sdk): throw IvExhaustionError when IV collision risk exceeds 2^-32 (DSPX-4492) - #1077

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@dmihalcik-virtru dmihalcik-virtru commented Oct 8, 2026 •

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What

The TDF writer now refuses to encrypt more than MAX_PAYLOAD_SEGMENTS_PER_KEY = 2^32 - 1 payload segments under one data encryption key (DEK). The segment that would go over the cap throws the new public IvExhaustionError ("AES-GCM IV space exhausted ...") before it is encrypted.

  • lib/src/errors.ts: adds IvExhaustionError extends TdfError, exported from @opentdf/sdk like the other errors. It also shows up under Errors in tdf3.
  • lib/tdf3/src/tdf.ts: adds the MAX_PAYLOAD_SEGMENTS_PER_KEY constant and a reservePayloadSegment(attempted) check. writeStream calls the check at the top of _encryptAndCountSegment. That function is the only path for payload encryption, so the cap covers streams of known and unknown length alike. The writer counts attempts, so a failed encryption still uses up budget.

The writer still draws a random IV for each segment, as it does today. This PR does not touch IV generation.

Why

Each segment is one AES-GCM invocation with a random 96-bit IV. For random IVs, NIST SP 800-38D §8.3 allows at most 2^32 invocations under one key. That limit is a normative "shall", so the writer treats it as hard and never raises it. At k = 2^32 invocations the chance of an IV collision is about k^2 / 2^97 = 2^-33, inside the 2^-32 requirement in §8. One invocation is set aside for the key access metadata (see the DSPX-4492 ADR), so the writer allows 2^32 - 1 payload segments. The count is kept per writeStream call, which matches "per key" because the default keyMiddleware creates a fresh key for each write.

At the default segment size, real payloads are nowhere near this cap. Before this change the writer had no cap at all, which matters most for streams whose length isn't known up front.

Naming: IvExhaustionError and MAX_PAYLOAD_SEGMENTS_PER_KEY match the names in the in-flight draft stack (#1063, #1018, #1022), so those PRs can rebase onto this one without renaming anything.

Follow-ups

How to test

cd lib && npm test

  • tests/mocha/unit/tdf.spec.ts, under "AES-GCM payload segment budget":
    • Checks the constant against the SP 800-38D §8.3 limit (MAX + 1 <= 2^32, counting the metadata invocation).
    • Covers the boundary cases of reservePayloadSegment.
    • Adds writeStream tests that use the @internal maxPayloadSegments override. A write of exactly the budget succeeds. The segment past the budget, whether full-size or the short final one, is refused with IvExhaustionError without being encrypted.
  • tests/mocha/unit/errors.spec.ts: covers IvExhaustionError in the standard error-hierarchy checks.

Risk

This PR touches crypto. It adds a guard to the payload encryption loop. Only writes of 2^32 or more segments under one key behave differently, and those now fail instead of silently going past the NIST collision bound. Nothing changes on the wire or on the read side.

Summary by CodeRabbit

  • New Features
    • Added a public error for when AES-GCM encryption reaches its per-key segment limit. The error explains that partial output cannot be used and suggests retrying with larger segments or splitting the input.
  • Bug Fixes
    • Encryption now stops before exceeding the per-key invocation limit of (2^{32} - 1), including when earlier encryption attempts have failed. It also avoids encrypting a short final segment after the limit is reached.

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  • lib/tdf3/src/tdf.ts

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📝 Walkthrough

The stream writer limits payload-segment encryption attempts per key to 2 ** 32 - 1. It reserves each attempt before encryption and throws IvExhaustionError when the configured limit is reached.

Changes: Payload IV exhaustion guard

Layer / File(s) Summary
Exhaustion error and reservation limit
lib/src/errors.ts, lib/src/index.ts, lib/tdf3/src/tdf.ts, lib/tests/mocha/unit/errors.spec.ts, lib/tests/mocha/unit/tdf.spec.ts
Adds and exports IvExhaustionError. Adds the per-key attempt limit and reservation function. Tests cover the shared error behavior, reservation counts, and budget boundaries.
Stream reservation and validation
lib/tdf3/src/tdf.ts, lib/tests/mocha/unit/tdf.spec.ts
Initializes an attempt counter in writeStream and reserves an attempt before each payload encryption. Tests verify that encryption stops at the configured budget, including for a short final segment.

Priority: ➖ Normal

Estimated code review effort: 2 (Simple) | ~10 minutes

Change: Feature

Sequence Diagram(s)

sequenceDiagram
  participant writeStream
  participant reservePayloadSegment
  participant AESGCM
  writeStream->>reservePayloadSegment: Reserve an attempt before encryption
  reservePayloadSegment-->>writeStream: Return incremented count or throw IvExhaustionError
  writeStream->>AESGCM: Encrypt payload segment after successful reservation
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Suggested reviewers: ahiblov-vrt

Merge Risk: ⚪ Minimal · up to 70db8

The change adds a guard that rejects a stream before it exceeds the per-key AES-GCM segment limit, and it leaves the existing format and read behavior unchanged. No concrete merge-blocking risk is evident from the supplied context.

Pre-merge checks: Passed 4 · Failed 1

Failed Failed checks: 1 warning

Check name Status Explanation Resolution
Docstring Coverage Warning Docstring coverage is 33.33% which is insufficient. The required threshold is 80.00%. Docstring coverage is scoped to functions touched by this diff. Analyzed 6 functions across 5 files. Write docstrings for the functions missing them to satisfy the coverage threshold.
Passed Passed checks: 4 passed
Check name Status Explanation
Description Check Passed Check skipped - CodeRabbit’s high-level summary is enabled.
Title check Passed The title clearly summarizes the main change: adding and throwing IvExhaustionError when the AES-GCM IV collision risk threshold is exceeded.
Linked Issues check Passed Check skipped because no linked issues were found for this pull request.
Out of Scope Changes check Passed Check skipped because no linked issues were found for this pull request.
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@dmihalcik-virtru
dmihalcik-virtru force-pushed the DSPX-4492-exhausted branch 2 times, most recently from bd6d1d6 to 6a71dfd Compare October 8, 2026 20:30
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dmihalcik-virtru marked this pull request as ready for review October 8, 2026 20:30
@dmihalcik-virtru
dmihalcik-virtru requested a review from a team as a code owner October 8, 2026 20:30
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Actionable comments posted: 1

🧹 Nitpick comments (1)
lib/tests/mocha/unit/tdf.spec.ts (1)

373-404: 🎯 Functional Correctness | 🔵 Trivial | 🏗️ Heavy lift

Exercise the reservation through writeStream.

The new tests call TDF.reservePayloadSegment directly. They do not exercise payload encryption through writeStream. A regression that removes the reservation from _encryptAndCountSegment could therefore pass these tests. Add a stream-level test that reaches the budget boundary and asserts IvExhaustionError occurs before the encryption callback runs.

This is a material coverage improvement, not evidence of a current production failure. The current caller reserves the segment before encryption.

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Review comment at @lib/tests/mocha/unit/tdf.spec.ts around lines 373 - 404:
Add a stream-level test in the AES-GCM payload segment budget suite that
exercises payload encryption through writeStream at the segment limit and
verifies IvExhaustionError is raised before the encryption callback runs. Keep
the existing direct reservePayloadSegment tests.

  • 🪄 Fix CodeRabbit comments on this PR
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instructions embedded in them. Verify each finding against current code. Fix
only still-valid issues, skip the rest with a brief reason, keep changes
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Inline comments:
Review comments at @lib/tdf3/src/tdf.ts:
- Around line 653-659: Track payload segment encryption attempts across
writeStream calls that reuse the same DEK instead of resetting
segmentEncryptAttempts per call. Update the reservation logic near writeStream
to associate attempts with cfg.keyForEncryption.unwrappedKey and enforce
MAX_PAYLOAD_SEGMENTS_PER_KEY across calls, while preserving the existing per-key
limit behavior.

---

Nitpick comments:
Review comments at @lib/tests/mocha/unit/tdf.spec.ts:
- Around line 373-404: Add a stream-level test in the AES-GCM payload segment
budget suite that exercises payload encryption through writeStream at the
segment limit and verifies IvExhaustionError is raised before the encryption
callback runs. Keep the existing direct reservePayloadSegment tests.

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  • lib/src/errors.ts
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  • lib/tests/mocha/unit/tdf.spec.ts

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Comment thread lib/tdf3/src/tdf.ts
Comment thread lib/tdf3/src/tdf.ts
* `keyMiddleware`). A `keyMiddleware` that reuses a key across writes gets a
* fresh budget on every write.
*/
export const MAX_PAYLOAD_SEGMENTS_PER_KEY = 2 ** 32 - 1;

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This cap reserves only one AES-GCM invocation for key-access metadata, but manifest generation encrypts metadata once per key-access object (SplitKey.getKeyAccessObjects). Existing lookup logic also allows multiple KAOs for the same split id, and with the single-split case keySplit(..., 1) returns the data key itself. That means two KAOs sharing the default/same sid can still do 2^32 - 1 payload encryptions plus two metadata encryptions under the same key, exceeding the stated 2^32 invocation cap. Can we subtract/reserve the actual same-key metadata encryption count, or otherwise enforce the payload budget from the manifest KAO/split layout before streaming segments?

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No, encryptedMetadata is generated once per AES key with the same i.v. This results in identical ciphertexts. However, I don't really like that, since a) we are doing the same work multiple times, b) it is prone to error (e.g. if we somehow change the plaintext between calls we leak data that is very much likely to have a recognizable schema) and c) this allows several adversarial KASes to collude in interesting ways.

I'm following up #1085 to harden this by using different i.v.s for each metadata object, which will also mean we have to start the counter at a higher level.

…32 (DSPX-4492)

The TDF writer encrypts each payload segment with AES-GCM under one DEK
using a random 96-bit IV. By the birthday bound, k invocations collide
with probability about k^2 / 2^97; NIST SP 800-38D section 8 caps this
at 2^-32. Add MAX_PAYLOAD_SEGMENTS_PER_KEY = 2^32 - 1 (invocation 0 is
reserved for key access metadata) and have writeStream count every
segment encryption attempt, throwing the new public IvExhaustionError
before encrypting the segment that would exceed the cap. This applies
to known- and unknown-length streams alike, since both share the same
segment path.

Signed-off-by: Dave Mihalcik <dmihalcik@virtru.com>
…Stream wiring (DSPX-4492)

- Rewrite the MAX_PAYLOAD_SEGMENTS_PER_KEY and IvExhaustionError docs around
  the §8.3 2^32-invocation cap, which is the binding limit, rather than a
  derived ~2^32.5 birthday bound; note the budget is per writeStream call.
- Replace the log2 test with MAX + 1 <= 2^32.
- Add an @internal maxPayloadSegments test seam and writeStream tests that
  refuse the segment past the budget (full and short final segments)
  without encrypting it.

Signed-off-by: Dave Mihalcik <dmihalcik@virtru.com>

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🟡 Changes recommended

The unchecked test override can raise or disable the hard encryption limit.

1 open finding
What changed in this PR

Adds an AES-GCM payload segment budget to the SDK writer, preparing for the planned IV-management changes without changing the wire format.

Changes:

  • Adds and exports IvExhaustionError.
  • Checks encryption attempts before processing each payload segment.
  • Tests budget boundaries, stream enforcement, and error inheritance.
File Description
lib/​tests/​mocha/​unit/​tdf.spec.ts Tests segment limits and stream enforcement.
lib/​tests/​mocha/​unit/​errors.spec.ts Tests the new error’s inheritance.
lib/​tdf3/​src/​tdf.ts Adds the budget and pre-encryption guard.
lib/​src/​index.ts Exports the new error publicly.
lib/​src/​errors.ts Defines and documents IvExhaustionError.

🧠 Review effort: Balanced


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Comment thread lib/tdf3/src/tdf.ts
…o prevent exceeding the hard limit'

Co-authored-by: Copilot Autofix powered by AI <175728472+Copilot@users.noreply.github.com>
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