fix(federation): address #494 review findings (FED-M2-04)

H1: Replace HS256/HMAC signing with real JWK signing (ES256/RS256/ES384)
    via jose SignJWT. Algorithm derived from JWK kty/crv. Provisioner
    password dropped as signing input; kept only as optional env var for
    PBES2-decrypt path at startup.
H2: Clamp cert TTL to 900s (15 min) in both DTO validator and issueCert().
    Default changed to 300s (5 min). @Max reduced to 15*60.
H3: Real CSR validation via @peculiar/x509: parse PEM, verify self-
    signature, reject weak keys (RSA<2048, bad EC curves), reject MD5/SHA-1.
    New validateCsr() throws CaServiceError code INVALID_CSR on failure.
H4: Replace hardcoded \x24 DER length in federation.tpl with dynamic
    printf "%c" (len ...) encoding. Add UUID-shape validation for grantId
    and subjectUserId in buildOtt() with code INVALID_GRANT_ID.
H5: Load JWK into KeyObject once (lazy, cached). provisionerKeyJson raw
    string not stored as class field. provisionerPassword not stored.

M1: Set JWT sub to CSR CN (extracted via @peculiar/x509) instead of URL.
M2: Add jti: crypto.randomUUID() to OTT claims.
M3: Drop top-level sha claim; keep only step.sha.
M4: extractSerial() throws CaServiceError code CERT_PARSE instead of
    returning 'unknown' on failure.
M5: Set timeout: 5000 on https.RequestOptions + req.setTimeout(5000).
M6: OTT signature verified with jose.jwtVerify in tests. Added real P-256
    CSR test via @peculiar/x509 generator. Added provisionerPassword
    leak-check test.
M7: Constructor validates STEP_CA_URL must be https://.

Verification: typecheck ✓, 385 tests pass (16 new), lint ✓, format ✓.

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>

apps/gateway/src/agent/provider-credentials.service.ts

@@ -1,62 +1,10 @@
 import { Inject, Injectable, Logger } from '@nestjs/common';
-import { createCipheriv, createDecipheriv, createHash, randomBytes } from 'node:crypto';
+import { seal, unseal } from '@mosaicstack/auth';
 import type { Db } from '@mosaicstack/db';
 import { providerCredentials, eq, and } from '@mosaicstack/db';
 import { DB } from '../database/database.module.js';
 import type { ProviderCredentialSummaryDto } from './provider-credentials.dto.js';
 
-const ALGORITHM = 'aes-256-gcm';
-const IV_LENGTH = 12; // 96-bit IV for GCM
-const TAG_LENGTH = 16; // 128-bit auth tag
-
-/**
- * Derive a 32-byte AES-256 key from BETTER_AUTH_SECRET using SHA-256.
- * The secret is assumed to be set in the environment.
- */
-function deriveEncryptionKey(): Buffer {
-  const secret = process.env['BETTER_AUTH_SECRET'];
-  if (!secret) {
-    throw new Error('BETTER_AUTH_SECRET is not set — cannot derive encryption key');
-  }
-  return createHash('sha256').update(secret).digest();
-}
-
-/**
- * Encrypt a plain-text value using AES-256-GCM.
- * Output format: base64(iv + authTag + ciphertext)
- */
-function encrypt(plaintext: string): string {
-  const key = deriveEncryptionKey();
-  const iv = randomBytes(IV_LENGTH);
-  const cipher = createCipheriv(ALGORITHM, key, iv);
-
-  const encrypted = Buffer.concat([cipher.update(plaintext, 'utf8'), cipher.final()]);
-  const authTag = cipher.getAuthTag();
-
-  // Combine iv (12) + authTag (16) + ciphertext and base64-encode
-  const combined = Buffer.concat([iv, authTag, encrypted]);
-  return combined.toString('base64');
-}
-
-/**
- * Decrypt a value encrypted by `encrypt()`.
- * Throws on authentication failure (tampered data).
- */
-function decrypt(encoded: string): string {
-  const key = deriveEncryptionKey();
-  const combined = Buffer.from(encoded, 'base64');
-
-  const iv = combined.subarray(0, IV_LENGTH);
-  const authTag = combined.subarray(IV_LENGTH, IV_LENGTH + TAG_LENGTH);
-  const ciphertext = combined.subarray(IV_LENGTH + TAG_LENGTH);
-
-  const decipher = createDecipheriv(ALGORITHM, key, iv);
-  decipher.setAuthTag(authTag);
-
-  const decrypted = Buffer.concat([decipher.update(ciphertext), decipher.final()]);
-  return decrypted.toString('utf8');
-}
-
 @Injectable()
 export class ProviderCredentialsService {
   private readonly logger = new Logger(ProviderCredentialsService.name);
@@ -74,7 +22,7 @@ export class ProviderCredentialsService {
     value: string,
     metadata?: Record<string, unknown>,
   ): Promise<void> {
-    const encryptedValue = encrypt(value);
+    const encryptedValue = seal(value);
 
     await this.db
       .insert(providerCredentials)
@@ -122,7 +70,7 @@ export class ProviderCredentialsService {
     }
 
     try {
-      return decrypt(row.encryptedValue);
+      return unseal(row.encryptedValue);
     } catch (err) {
       this.logger.error(
         `Failed to decrypt credential for user=${userId} provider=${provider}`,

apps/gateway/src/federation/__tests__/peer-key.spec.ts

@@ -0,0 +1,63 @@
+import { describe, it, expect, beforeEach, afterEach } from 'vitest';
+import { sealClientKey, unsealClientKey } from '../peer-key.util.js';
+
+const TEST_SECRET = 'test-secret-for-peer-key-unit-tests-only';
+
+const TEST_PEM = `-----BEGIN PRIVATE KEY-----
+MIIEvQIBADANBgkqhkiG9w0BAQEFAASCBKcwggSjAgEAAoIBAQC7o4qne60TB3wo
+pCOW8QqstpxEBpnFo37JxLYEJbpE3gUlJajsHv9UWRQ7m5B7n+MBXwTCQqMEY8Wl
+kHv9tGgz1YGwzBjNKxPJXE6pPTXQ1Oa0VB9l3qHdqF5HtZoJzE0c6dO8HJ5YUVL
+-----END PRIVATE KEY-----`;
+
+let savedSecret: string | undefined;
+
+beforeEach(() => {
+  savedSecret = process.env['BETTER_AUTH_SECRET'];
+  process.env['BETTER_AUTH_SECRET'] = TEST_SECRET;
+});
+
+afterEach(() => {
+  if (savedSecret === undefined) {
+    delete process.env['BETTER_AUTH_SECRET'];
+  } else {
+    process.env['BETTER_AUTH_SECRET'] = savedSecret;
+  }
+});
+
+describe('peer-key seal/unseal', () => {
+  it('round-trip: unsealClientKey(sealClientKey(pem)) returns original pem', () => {
+    const sealed = sealClientKey(TEST_PEM);
+    const roundTripped = unsealClientKey(sealed);
+    expect(roundTripped).toBe(TEST_PEM);
+  });
+
+  it('non-determinism: sealClientKey produces different ciphertext each call', () => {
+    const sealed1 = sealClientKey(TEST_PEM);
+    const sealed2 = sealClientKey(TEST_PEM);
+    expect(sealed1).not.toBe(sealed2);
+  });
+
+  it('at-rest: sealed output does not contain plaintext PEM content', () => {
+    const sealed = sealClientKey(TEST_PEM);
+    expect(sealed).not.toContain('PRIVATE KEY');
+    expect(sealed).not.toContain(
+      'MIIEvQIBADANBgkqhkiG9w0BAQEFAASCBKcwggSjAgEAAoIBAQC7o4qne60TB3wo',
+    );
+  });
+
+  it('tamper: flipping a byte in the sealed payload causes unseal to throw', () => {
+    const sealed = sealClientKey(TEST_PEM);
+    const buf = Buffer.from(sealed, 'base64');
+    // Flip a byte in the middle of the buffer (past IV and authTag)
+    const midpoint = Math.floor(buf.length / 2);
+    buf[midpoint] = buf[midpoint]! ^ 0xff;
+    const tampered = buf.toString('base64');
+    expect(() => unsealClientKey(tampered)).toThrow();
+  });
+
+  it('missing secret: unsealClientKey throws when BETTER_AUTH_SECRET is unset', () => {
+    const sealed = sealClientKey(TEST_PEM);
+    delete process.env['BETTER_AUTH_SECRET'];
+    expect(() => unsealClientKey(sealed)).toThrow('BETTER_AUTH_SECRET is not set');
+  });
+});

apps/gateway/src/federation/peer-key.util.ts

@@ -0,0 +1,9 @@
+import { seal, unseal } from '@mosaicstack/auth';
+
+export function sealClientKey(privateKeyPem: string): string {
+  return seal(privateKeyPem);
+}
+
+export function unsealClientKey(sealedKey: string): string {
+  return unseal(sealedKey);
+}

deploy/portainer/federated-test.stack.yml

@@ -36,6 +36,12 @@
 #   tested locally — gateway boots, imports resolve, tier-detector runs.
 #   Update digest here when promoting a new build.
 #
+# HEALTHCHECK NOTE (2026-04-21)
+#   Switched from busybox wget to node http.get on 127.0.0.1 (not localhost) to
+#   avoid IPv6 resolution issues on Alpine. Retries increased to 5 and
+#   start_period to 60s to cover the NestJS/GC cold-start window (~40-50s).
+#   restart_policy set to `any` so SIGTERM/clean-exit also triggers restart.
+#
 # NOTE: This is a TEST template — production deployments use a separate
 #       parameterised template with stricter resource limits and secrets.
 
@@ -76,7 +82,7 @@ services:
     deploy:
       replicas: 1
       restart_policy:
-        condition: on-failure
+        condition: any
         delay: 5s
         max_attempts: 3
       labels:
@@ -88,11 +94,15 @@ services:
         - 'traefik.http.routers.${STACK_NAME}.tls.certresolver=letsencrypt'
         - 'traefik.http.services.${STACK_NAME}.loadbalancer.server.port=3000'
     healthcheck:
-      test: ['CMD', 'wget', '-qO-', 'http://localhost:3000/health']
+      test:
+        - 'CMD'
+        - 'node'
+        - '-e'
+        - "require('http').get('http://127.0.0.1:3000/health',r=>process.exit(r.statusCode===200?0:1)).on('error',()=>process.exit(1))"
       interval: 30s
       timeout: 5s
-      retries: 3
-      start_period: 20s
+      retries: 5
+      start_period: 60s
     depends_on:
       - postgres
       - valkey

docs/federation/SETUP.md

@@ -118,6 +118,12 @@ docker compose -f docker-compose.federated.yml logs valkey-federated
 
 If Valkey is running, verify your firewall allows 6380. On macOS, Docker Desktop may require binding to `host.docker.internal` instead of `localhost`.
 
+## Key rotation (deferred)
+
+Federation peer private keys (`federation_peers.client_key_pem`) are sealed at rest using AES-256-GCM with a key derived from `BETTER_AUTH_SECRET` via SHA-256. If `BETTER_AUTH_SECRET` is rotated, all sealed `client_key_pem` values in the database become unreadable and must be re-sealed with the new key before rotation completes.
+
+The full key rotation procedure (decrypt all rows with old key, re-encrypt with new key, atomically swap the secret) is out of scope for M2. Operators must not rotate `BETTER_AUTH_SECRET` without a migration plan for all sealed federation peer keys.
+
 ## OID Assignments — Mosaic Internal OID Arc
 
 Mosaic uses the private enterprise arc `1.3.6.1.4.1.99999` for custom X.509

packages/auth/src/index.ts

@@ -10,3 +10,4 @@ export {
   type SsoTeamSyncConfig,
   type SupportedSsoProviderId,
 } from './sso.js';
+export { seal, unseal } from './seal.js';

packages/auth/src/seal.ts

@@ -0,0 +1,52 @@
+import { createCipheriv, createDecipheriv, createHash, randomBytes } from 'node:crypto';
+
+const ALGORITHM = 'aes-256-gcm';
+const IV_LENGTH = 12; // 96-bit IV for GCM
+const TAG_LENGTH = 16; // 128-bit auth tag
+
+/**
+ * Derive a 32-byte AES-256 key from BETTER_AUTH_SECRET using SHA-256.
+ * Throws if BETTER_AUTH_SECRET is not set.
+ */
+function deriveKey(): Buffer {
+  const secret = process.env['BETTER_AUTH_SECRET'];
+  if (!secret) {
+    throw new Error('BETTER_AUTH_SECRET is not set — cannot derive encryption key');
+  }
+  return createHash('sha256').update(secret).digest();
+}
+
+/**
+ * Seal a plaintext string using AES-256-GCM.
+ * Output format: base64(IV || authTag || ciphertext)
+ */
+export function seal(plaintext: string): string {
+  const key = deriveKey();
+  const iv = randomBytes(IV_LENGTH);
+  const cipher = createCipheriv(ALGORITHM, key, iv);
+
+  const encrypted = Buffer.concat([cipher.update(plaintext, 'utf8'), cipher.final()]);
+  const authTag = cipher.getAuthTag();
+
+  const combined = Buffer.concat([iv, authTag, encrypted]);
+  return combined.toString('base64');
+}
+
+/**
+ * Unseal a value sealed by `seal()`.
+ * Throws on authentication failure (tampered data) or if BETTER_AUTH_SECRET is unset.
+ */
+export function unseal(encoded: string): string {
+  const key = deriveKey();
+  const combined = Buffer.from(encoded, 'base64');
+
+  const iv = combined.subarray(0, IV_LENGTH);
+  const authTag = combined.subarray(IV_LENGTH, IV_LENGTH + TAG_LENGTH);
+  const ciphertext = combined.subarray(IV_LENGTH + TAG_LENGTH);
+
+  const decipher = createDecipheriv(ALGORITHM, key, iv);
+  decipher.setAuthTag(authTag);
+
+  const decrypted = Buffer.concat([decipher.update(ciphertext), decipher.final()]);
+  return decrypted.toString('utf8');
+}