fix(emails): address Copilot review feedback (NPPD-1524)

- card-expiry-warning unit test: assert cancellation and woo-renewal-reminder
  indices are not false before comparing ordering.
- card-expiry-warning smoke test: add Reader Activation prereq check so it
  fails fast instead of silently capturing 0 emails; drop the temporary
  "delete after merge" notice; add a README documenting tests/integration/.
- Card_Expiry_Warning::maybe_send_warning(): use $customer->first_name as a
  fallback when subscription billing_first_name is empty.
- Card_Expiry_Warning::clear_sent_flag(): drop the unused $new_payment_method
  parameter and matching accepted_args from the action.

Author: kmwilkerson

includes/plugins/woocommerce-subscriptions/class-card-expiry-warning.php

@@ -44,12 +44,7 @@ public static function init() {
 		add_filter( 'newspack_email_configs', [ __CLASS__, 'add_email_config' ] );
 		add_action( 'init', [ __CLASS__, 'schedule_cron' ] );
 		add_action( self::CRON_HOOK, [ __CLASS__, 'scan_expiring_cards' ] );
-		add_action(
-			'woocommerce_subscription_payment_method_updated',
-			[ __CLASS__, 'clear_sent_flag' ],
-			10,
-			2
-		);
+		add_action( 'woocommerce_subscription_payment_method_updated', [ __CLASS__, 'clear_sent_flag' ] );
 		add_action( 'newspack_deactivation', [ __CLASS__, 'unschedule_cron' ] );
 	}
 
@@ -256,10 +251,15 @@ private static function maybe_send_warning( $subscription, $token ) {
 			? date_i18n( get_option( 'date_format', 'F j, Y' ), $subscription->get_time( 'next_payment' ) )
 			: __( 'your next renewal', 'newspack-plugin' );
 
+		$first_name = $subscription->get_billing_first_name();
+		if ( '' === $first_name ) {
+			$first_name = $customer->first_name;
+		}
+
 		$placeholders = [
 			[
 				'template' => '*BILLING_FIRST_NAME*',
-				'value'    => esc_html( $subscription->get_billing_first_name() ),
+				'value'    => esc_html( $first_name ),
 			],
 			[
 				'template' => '*CARD_LAST_4*',
@@ -296,10 +296,9 @@ private static function maybe_send_warning( $subscription, $token ) {
 	 *
 	 * Hooked to 'woocommerce_subscription_payment_method_updated'.
 	 *
-	 * @param \WC_Subscription $subscription     The subscription.
-	 * @param string           $new_payment_method The new payment method ID.
+	 * @param \WC_Subscription $subscription The subscription.
 	 */
-	public static function clear_sent_flag( $subscription, $new_payment_method ) {
+	public static function clear_sent_flag( $subscription ) {
 		$subscription->delete_meta_data( self::SENT_META );
 		$subscription->save();
 	}

tests/integration/README.md

@@ -0,0 +1,21 @@
+# Integration Smoke Tests
+
+Integration smoke tests that exercise Newspack features against a real WordPress + WooCommerce environment. Unlike the PHPUnit suite under `tests/unit-tests/`, these scripts are run manually via `wp eval-file` and require the full plugin stack to be active.
+
+## Running
+
+```bash
+wp eval-file tests/integration/<script>.php
+```
+
+Each script prints `PASS`/`FAIL` lines per scenario, a final `N/M PASSED` summary, and exits non-zero on any failure. Scripts create their own fixtures and clean up after themselves.
+
+## Scripts
+
+### `card-expiry-warning-smoke.php`
+
+End-to-end coverage for the Card Expiry Warning email (`includes/plugins/woocommerce-subscriptions/class-card-expiry-warning.php`).
+
+**Requires:** WooCommerce, WooCommerce Subscriptions, Newspack Newsletters, and Reader Activation enabled.
+
+Exercises cron scheduling, happy-path send, idempotency, the payment-method-update flag clear, new-card re-send, and the unattached-card no-op.

tests/integration/card-expiry-warning-smoke.php

@@ -14,19 +14,18 @@
  *  2. Happy-path send (token → subscription → email)
  *  3. Idempotency (no duplicate send)
  *  4. clear_sent_flag() handler clears meta (called directly; the full
- *     woocommerce_subscription_payment_method_updated action fatals on
- *     WCS PayPal's hook which expects 3 args)
+ *     woocommerce_subscription_payment_method_updated action triggers
+ *     third-party hooks like WCS PayPal that fatal on a minimal fixture)
  *  5. New card triggers new send
  *  6. Unattached card does not trigger email
  *  7. Cleanup
  *
- * Delete this file after the PR merges.
- *
  * @package Newspack\Tests
  */
 
 use Newspack\Card_Expiry_Warning;
 use Newspack\Emails;
+use Newspack\Reader_Activation;
 
 // ── Globals ──────────────────────────────────────────────────────────
 // wp eval-file runs via eval(), so file-scope vars are local to the eval
@@ -82,6 +81,14 @@ function smoke_fail( string $label, string $detail = '' ): void {
 if ( ! function_exists( 'wcs_create_subscription' ) ) {
 	WP_CLI::error( 'wcs_create_subscription() not available. Aborting.' );
 }
+
+// Card_Expiry_Warning::init() only registers the email config when
+// WooCommerce_Subscriptions::is_enabled() returns true, which in turn
+// requires Reader Activation to be enabled. Without this, scan_expiring_cards()
+// silently captures 0 emails and the test gives a misleading failure.
+if ( ! Reader_Activation::is_enabled() ) {
+	WP_CLI::error( 'Reader Activation is not enabled. Aborting.' );
+}
 WP_CLI::log( 'Prerequisites OK.' );
 
 // ── Intercept wp_mail via pre_wp_mail ────────────────────────────────
@@ -290,10 +297,10 @@ function () {
 
 // Call clear_sent_flag() directly rather than firing the full
 // woocommerce_subscription_payment_method_updated action. That action
-// triggers third-party hooks (WCS PayPal, etc.) whose callbacks expect
-// 3 args and fatal with our minimal test fixture.
+// triggers third-party hooks (WCS PayPal, etc.) that fatal with our
+// minimal test fixture.
 $subscription = wcs_get_subscription( $sub_id );
-Card_Expiry_Warning::clear_sent_flag( $subscription, 'stripe' );
+Card_Expiry_Warning::clear_sent_flag( $subscription );
 
 $subscription = wcs_get_subscription( $sub_id );
 $meta_val     = $subscription->get_meta( '_newspack_card_expiry_warning_sent', true );

tests/unit-tests/card-expiry-warning.php

@@ -181,6 +181,8 @@ public function test_registry_entry_order() {
 		$renewal_reminder_idx = array_search( 'woo-renewal-reminder', $slugs, true );
 
 		$this->assertNotFalse( $card_expiry_idx, 'card-expiry-warning should be in the registry.' );
+		$this->assertNotFalse( $cancellation_idx, 'cancellation should be in the registry.' );
+		$this->assertNotFalse( $renewal_reminder_idx, 'woo-renewal-reminder should be in the registry.' );
 		$this->assertGreaterThan( $cancellation_idx, $card_expiry_idx, 'card-expiry-warning should appear after cancellation.' );
 		$this->assertLessThan( $renewal_reminder_idx, $card_expiry_idx, 'card-expiry-warning should appear before woo-renewal-reminder.' );
 	}