Summary

Fixes CUDA and Vulkan GPU acceleration binaries failing to download/activate on Windows systems where the PowerShell Microsoft.PowerShell.Archive module cannot load.

Root cause: Expand-Archive relies on Microsoft.PowerShell.Archive which fails to auto-load on some Windows configurations, silently breaking all zip extraction in both WhisperCudaManager and LlamaVulkanManager.

Additional issues fixed:

• After successful CUDA/Vulkan download, the running whisper/llama server was not restarted, so the CPU binary continued to be used until app restart
• CUDA downloads had no concurrent download guard, allowing multiple parallel downloads from rapid UI clicks
• CUDA download errors were silently swallowed with no logging

Changes

src/helpers/whisperCudaManager.js

• Replace Expand-Archive with tar.exe (built into Windows 10+), falling back to PowerShell if tar is unavailable
• Add recursive _findFile()/_findFiles() for binary search in extracted archives (matches existing LlamaVulkanManager pattern)
• Add _downloading flag to prevent concurrent downloads
• Restructure try/finally so the download flag resets on any error

src/helpers/llamaVulkanManager.js

• Replace Expand-Archive with tar.exe + PowerShell fallback (same fix)

src/helpers/ipcHandlers.js

• Restart whisper-server after CUDA binary download/delete
• Restart llama-server after Vulkan binary download
• Add error logging for CUDA and Vulkan download failures
• Add downloading state to CUDA status IPC response

Test plan

• Download CUDA binary on Windows — verify extraction succeeds and GPU acceleration activates immediately
• Download Vulkan binary on Windows — verify extraction succeeds and GPU acceleration activates immediately
• Click download button rapidly — verify only one download runs at a time
• Delete CUDA/Vulkan binary — verify server falls back to CPU binary
• Cancel mid-download — verify clean state recovery
• Verify Linux extraction (unzip) still works unchanged

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