viirya commented on code in PR #25428:
URL: https://github.com/apache/datafusion/pull/25428#discussion_r4054345925


##########
datafusion/physical-plan/src/sorts/builder.rs:
##########
@@ -129,6 +129,201 @@ impl BatchBuilder {
         &self.schema
     }
 
+    /// Release fully consumed batches after a merge drains at an input 
boundary.
+    /// Keeping their dictionaries can otherwise enlarge the next output even
+    /// though none of its rows refer to those batches.
+    pub(super) fn discard_consumed_batches(&mut self) -> Result<()> {
+        assert_or_internal_err!(
+            self.indices.is_empty(),
+            "pending merge rows must be emitted before discarding source 
batches"
+        );
+        self.retain_current_batches(true);
+        // Bypassed spill merges only update their local accounting here; their
+        // real pool reservation remains attached to the outer merge stream.
+        self.release_unused_memory();
+        Ok(())
+    }
+
+    /// Whether replacing an exhausted input would exceed the allowance for
+    /// retained source batches and materializing output together. This 
preserves
+    /// the caller's existing source/output estimate; cursor, read-ahead and 
IPC
+    /// allocations still depend on the merge's heuristic workspace 
reservation.
+    pub(super) fn should_flush_before_input(

Review Comment:
   The doc explains what the estimate covers but not how it behaves when the 
budget is tight, which is the question a reader debugging a fragmented 
intermediate run will arrive with.
   
   The floor is safe, and saying so is reassuring: the check runs only at input 
batch boundaries, never per row, and returns `false` on `is_empty()`, so the 
worst case degenerates to one output batch per input batch — exactly the 
unconditional flushing this replaces — and can never produce a zero-row batch 
or fail to make progress.
   
   Something like: "When the allowance is small this degrades to flushing at 
every input boundary, which is the previous behaviour; it never blocks 
progress." 



##########
datafusion/physical-plan/src/sorts/multi_level_merge.rs:
##########
@@ -373,95 +424,158 @@ impl MultiLevelMergeBuilder {
                 let minimum_number_of_required_streams =
                     2_usize.saturating_sub(self.sorted_streams.len());
 
-                let (sorted_spill_files, buffer_size) = match self
-                    .get_sorted_spill_files_to_merge(
-                        2,
-                        // we must have at least 2 streams to merge
-                        minimum_number_of_required_streams,
-                        &mut memory_reservation,
-                        allow_minimum_without_headroom,
-                    )? {
-                    SpillFilesToMerge::Ready(sorted_spill_files, buffer_size) 
=> {
-                        (sorted_spill_files, buffer_size)
+                let selection = self.get_sorted_spill_files_to_merge(
+                    2,
+                    minimum_number_of_required_streams,
+                    &mut memory_reservation,
+                    allow_minimum_without_headroom,
+                )?;
+                let (mut spills, mut buffer_size) = match selection {
+                    SpillFilesToMerge::Ready(spills, buffer_size) => {
+                        (spills, buffer_size)
                     }
-                    // Not enough memory to seat 2 streams. Re-spill the 
blocking file
-                    // smaller and retry. `get_sorted_spill_files_to_merge` 
already freed
-                    // the reservation and `self.sorted_streams` is untouched, 
so the
-                    // retry starts clean.
                     SpillFilesToMerge::SplitThenRetry(index) => {
                         return Ok(MergeStep::SplitThenRetry(index));
                     }
                 };
 
-                // Don't account for existing streams memory
-                // as we are not holding the memory for them
-                let mut sorted_streams = mem::take(&mut self.sorted_streams);
-
-                let is_only_merging_memory_streams = 
sorted_spill_files.is_empty();
-
-                // If no spill files were selected (e.g. all too large for
-                // available memory but enough in-memory streams exist),
-                // return the pre-reserved bytes to self.reservation so
-                // create_new_merge_sort can transfer them to the merge
-                // stream's BatchBuilder.
-                if is_only_merging_memory_streams {
-                    mem::swap(&mut self.reservation, &mut memory_reservation);
+                let original_count = spills.len();
+                let original_buffer_size = buffer_size;
+                let original_memory = memory_reservation.size();
+                if self.reserve_replay_headroom
+                    && self.widen_intermediate_merges
+                    && !allow_minimum_without_headroom
+                    && buffer_size > 1
+                    && self.sorted_streams.is_empty()
+                    && !spills.is_empty()
+                {
+                    // Trade read-ahead for fan-in without taking any more pool
+                    // memory. Other partitions retain exactly the space left 
by
+                    // the original admission, even while they replay 
aggregates.
+                    // Keep one run for the final merge and its replay 
headroom.
+                    let candidates = spills
+                        .iter()
+                        .chain(&self.sorted_spill_files)
+                        .take(spills.len() + self.sorted_spill_files.len() - 1)
+                        .map(|(spill, _)| spill);
+                    let widened_count = spill_merge_memory_requirements(
+                        candidates,
+                        1,
+                        self.max_spill_merge_fan_in(),
+                    )
+                    .take_while(|needed| *needed <= original_memory)
+                    .count();
+                    if widened_count > original_count {
+                        buffer_size = 1;
+                        spills.extend(
+                            self.sorted_spill_files
+                                .drain(..widened_count - original_count),
+                        );
+                    }
                 }
+                let reservation = Arc::new(memory_reservation);
+                let widened = spills.len() > original_count;
+                let retry_reservation = widened.then(|| 
Arc::clone(&reservation));
+                let (stream, batch_size_limit) =
+                    self.merge_selected_runs(&spills, buffer_size, 
reservation, widened)?;
+                let retry = retry_reservation.map(|reservation| 
IntermediateMergeRetry {
+                    spills,
+                    original_count,
+                    buffer_size: original_buffer_size,
+                    reservation,
+                });
+                Ok(MergeStep::Stream {
+                    stream,
+                    batch_size_limit,
+                    retry,
+                })
+            }
+        }
+    }
 
-                // Cap the merge output at the smallest limit among the runs 
we're
-                // about to merge. Runs that were shrunk for skew carry a 
smaller limit,
-                // if none do, every run carries `self.batch_size` and the 
merge runs at
-                // the full batch size. The output stream is tagged with the 
same limit
-                // (see the `MergeStep::Stream` returns below) so a re-spilled
-                // intermediate run stays shrunk and won't rebuild an 
oversized batch on
-                // a later pass.
-                let mut output_batch_size = self.batch_size;
-                for (spill, batch_size_limit) in sorted_spill_files {
-                    let stream = self
-                        .spill_manager
-                        .clone()
-                        .with_batch_read_buffer_capacity(buffer_size)
-                        .read_spill_as_stream(
-                            spill.file,
-                            Some(spill.max_record_batch_memory),
-                        )?;
-                    output_batch_size = 
output_batch_size.min(batch_size_limit);
-                    sorted_streams.push(stream);
-                }
-                let merge_sort_stream = self.create_new_merge_sort(
+    /// Build a stream from an already admitted selection. The reservation can
+    /// also be held by a retry guard until an intermediate writer finishes.
+    fn merge_selected_runs(

Review Comment:
   Worth pinning this invariant here with a `debug_assert`.
   
   `merge.rs:302` indexes `budget.input_batch_sizes[winner_stream]`, but the 
stream vector built below starts with the in-memory streams from 
`mem::take(&mut self.sorted_streams)` and appends the spill streams after them, 
while `input_batch_sizes` is built from `sorted_spill_files` alone. The indices 
line up only because widening requires `self.sorted_streams.is_empty()` at line 
449, three layers up from here.
   
   Not a live bug — I traced every `sorted_streams` mutation between line 449 
and line 507 and there is none, and the `input_batch_sizes.len() == 
streams.len()` check in `streaming_merge.rs` would catch a mismatch as an 
internal error rather than a silent misattribution. But nothing at this 
signature says `bound_batch_memory` implies "no in-memory streams", so a later 
change that admits in-memory streams alongside a widened pass would be 
attributing the wrong per-input size to each stream.
   
   A `debug_assert!(!bound_batch_memory || sorted_streams.is_empty())` after 
the `mem::take`, or a line on `bound_batch_memory` in the doc comment, would 
make the coupling local.



##########
datafusion/physical-plan/src/sorts/multi_level_merge.rs:
##########
@@ -373,95 +424,158 @@ impl MultiLevelMergeBuilder {
                 let minimum_number_of_required_streams =
                     2_usize.saturating_sub(self.sorted_streams.len());
 
-                let (sorted_spill_files, buffer_size) = match self
-                    .get_sorted_spill_files_to_merge(
-                        2,
-                        // we must have at least 2 streams to merge
-                        minimum_number_of_required_streams,
-                        &mut memory_reservation,
-                        allow_minimum_without_headroom,
-                    )? {
-                    SpillFilesToMerge::Ready(sorted_spill_files, buffer_size) 
=> {
-                        (sorted_spill_files, buffer_size)
+                let selection = self.get_sorted_spill_files_to_merge(
+                    2,
+                    minimum_number_of_required_streams,
+                    &mut memory_reservation,
+                    allow_minimum_without_headroom,
+                )?;
+                let (mut spills, mut buffer_size) = match selection {
+                    SpillFilesToMerge::Ready(spills, buffer_size) => {
+                        (spills, buffer_size)
                     }
-                    // Not enough memory to seat 2 streams. Re-spill the 
blocking file
-                    // smaller and retry. `get_sorted_spill_files_to_merge` 
already freed
-                    // the reservation and `self.sorted_streams` is untouched, 
so the
-                    // retry starts clean.
                     SpillFilesToMerge::SplitThenRetry(index) => {
                         return Ok(MergeStep::SplitThenRetry(index));
                     }
                 };
 
-                // Don't account for existing streams memory
-                // as we are not holding the memory for them
-                let mut sorted_streams = mem::take(&mut self.sorted_streams);
-
-                let is_only_merging_memory_streams = 
sorted_spill_files.is_empty();
-
-                // If no spill files were selected (e.g. all too large for
-                // available memory but enough in-memory streams exist),
-                // return the pre-reserved bytes to self.reservation so
-                // create_new_merge_sort can transfer them to the merge
-                // stream's BatchBuilder.
-                if is_only_merging_memory_streams {
-                    mem::swap(&mut self.reservation, &mut memory_reservation);
+                let original_count = spills.len();
+                let original_buffer_size = buffer_size;
+                let original_memory = memory_reservation.size();
+                if self.reserve_replay_headroom
+                    && self.widen_intermediate_merges
+                    && !allow_minimum_without_headroom
+                    && buffer_size > 1
+                    && self.sorted_streams.is_empty()
+                    && !spills.is_empty()
+                {
+                    // Trade read-ahead for fan-in without taking any more pool
+                    // memory. Other partitions retain exactly the space left 
by
+                    // the original admission, even while they replay 
aggregates.
+                    // Keep one run for the final merge and its replay 
headroom.
+                    let candidates = spills
+                        .iter()
+                        .chain(&self.sorted_spill_files)
+                        .take(spills.len() + self.sorted_spill_files.len() - 1)
+                        .map(|(spill, _)| spill);
+                    let widened_count = spill_merge_memory_requirements(
+                        candidates,
+                        1,
+                        self.max_spill_merge_fan_in(),
+                    )
+                    .take_while(|needed| *needed <= original_memory)
+                    .count();
+                    if widened_count > original_count {
+                        buffer_size = 1;
+                        spills.extend(
+                            self.sorted_spill_files
+                                .drain(..widened_count - original_count),
+                        );
+                    }
                 }
+                let reservation = Arc::new(memory_reservation);
+                let widened = spills.len() > original_count;
+                let retry_reservation = widened.then(|| 
Arc::clone(&reservation));
+                let (stream, batch_size_limit) =
+                    self.merge_selected_runs(&spills, buffer_size, 
reservation, widened)?;
+                let retry = retry_reservation.map(|reservation| 
IntermediateMergeRetry {
+                    spills,
+                    original_count,
+                    buffer_size: original_buffer_size,
+                    reservation,
+                });
+                Ok(MergeStep::Stream {
+                    stream,
+                    batch_size_limit,
+                    retry,
+                })
+            }
+        }
+    }
 
-                // Cap the merge output at the smallest limit among the runs 
we're
-                // about to merge. Runs that were shrunk for skew carry a 
smaller limit,
-                // if none do, every run carries `self.batch_size` and the 
merge runs at
-                // the full batch size. The output stream is tagged with the 
same limit
-                // (see the `MergeStep::Stream` returns below) so a re-spilled
-                // intermediate run stays shrunk and won't rebuild an 
oversized batch on
-                // a later pass.
-                let mut output_batch_size = self.batch_size;
-                for (spill, batch_size_limit) in sorted_spill_files {
-                    let stream = self
-                        .spill_manager
-                        .clone()
-                        .with_batch_read_buffer_capacity(buffer_size)
-                        .read_spill_as_stream(
-                            spill.file,
-                            Some(spill.max_record_batch_memory),
-                        )?;
-                    output_batch_size = 
output_batch_size.min(batch_size_limit);
-                    sorted_streams.push(stream);
-                }
-                let merge_sort_stream = self.create_new_merge_sort(
+    /// Build a stream from an already admitted selection. The reservation can
+    /// also be held by a retry guard until an intermediate writer finishes.
+    fn merge_selected_runs(
+        &mut self,
+        sorted_spill_files: &[(SortedSpillFile, usize)],
+        buffer_size: usize,
+        memory_reservation: Arc<MemoryReservation>,
+        bound_batch_memory: bool,
+    ) -> Result<(SendableRecordBatchStream, usize)> {
+        // Don't account for existing streams memory
+        // as we are not holding the memory for them
+        let mut sorted_streams = mem::take(&mut self.sorted_streams);
+
+        let is_only_merging_memory_streams = sorted_spill_files.is_empty();
+
+        // If no spill files were selected (e.g. all too large for
+        // available memory but enough in-memory streams exist),
+        // return the pre-reserved bytes to self.reservation so
+        // create_new_merge_sort can transfer them to the merge
+        // stream's BatchBuilder.
+        if is_only_merging_memory_streams {
+            self.reservation = Arc::try_unwrap(memory_reservation)
+                .expect("in-memory merges do not retain a spill retry 
reservation");
+            return Ok((
+                self.create_new_merge_sort(
                     sorted_streams,
-                    // If we have no sorted spill files left, this is the last 
run
                     self.sorted_spill_files.is_empty(),
-                    is_only_merging_memory_streams,
-                    output_batch_size,
-                )?;
-
-                // If we're only merging memory streams, we don't need to 
attach the memory reservation
-                // as it's empty
-                if is_only_merging_memory_streams {
-                    assert_eq!(
-                        memory_reservation.size(),
-                        0,
-                        "when only merging memory streams, we should not have 
any memory reservation and let the merge sort handle the memory"
-                    );
+                    true,
+                    self.batch_size,
+                    None,
+                )?,
+                self.batch_size,
+            ));
+        }
 
-                    Ok(MergeStep::Stream {
-                        stream: merge_sort_stream,
-                        batch_size_limit: output_batch_size,
-                    })
-                } else {
-                    // Attach the memory reservation to the stream to make 
sure we have enough memory
-                    // throughout the merge process as we bypassed the memory 
pool for the merge sort stream
-                    Ok(MergeStep::Stream {
-                        stream: Box::pin(StreamAttachedReservation::new(
-                            merge_sort_stream,
-                            memory_reservation,
-                        )),
-                        batch_size_limit: output_batch_size,
-                    })
-                }
-            }
+        // Cap the merge output at the smallest limit among the runs we're
+        // about to merge. Runs that were shrunk for skew carry a smaller 
limit,
+        // if none do, every run carries `self.batch_size` and the merge runs 
at
+        // the full batch size. The output stream is tagged with the same limit
+        // (see the `MergeStep::Stream` returns below) so a re-spilled
+        // intermediate run stays shrunk and won't rebuild an oversized batch 
on
+        // a later pass.
+        let mut output_batch_size = self.batch_size;
+        for (spill, batch_size_limit) in sorted_spill_files {
+            let stream = self
+                .spill_manager
+                .clone()
+                .with_batch_read_buffer_capacity(buffer_size)
+                .read_spill_as_stream(
+                    Arc::clone(&spill.file),
+                    Some(spill.max_record_batch_memory),
+                )?;
+            output_batch_size = output_batch_size.min(*batch_size_limit);
+            sorted_streams.push(stream);
         }
+        let batch_memory_budget = bound_batch_memory.then(|| {

Review Comment:
   `memory_limit` here is `sum(max_record_batch_memory) * 2`, and the comment 
says it is "the same two-batch allowance used for spill admission". That checks 
out — `get_reserved_bytes_for_record_batch_size(x, x)` is `x + x`, so admission 
reserves `2 * max_batch_memory` per run per buffer, and this equals the 
admitted per-run allowance at `buffer_len == 1`, which is what a widened pass 
runs at.
   
   That equivalence is load-bearing and only holds while widening forces 
`buffer_size = 1`. Worth naming the `buffer_len == 1` assumption in the comment 
so a future change to the widened read-ahead does not silently leave this 
budget over-generous.



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