Ensure order state handles with partial shipment

app/code/Magento/Sales/Model/Order/Item.php

@@ -41,6 +41,8 @@ class Item extends AbstractModel implements OrderItemInterface
     // When qty ordered = qty canceled
     const STATUS_PARTIAL = 6;
 
+    const ZERO_AMOUNT = 0.0;
+
     // If [qty shipped or(max of two) qty invoiced + qty canceled + qty returned]
     // < qty ordered
     const STATUS_MIXED = 7;
@@ -232,7 +234,21 @@ public function getQtyToShip()
      */
     public function getSimpleQtyToShip()
     {
-        $qty = $this->getQtyOrdered() - max($this->getQtyShipped(), $this->getQtyRefunded()) - $this->getQtyCanceled();
+        if ($this->getIsVirtual() /*|| $this->getQtyInvoiced() == 0*/) {
+            return self::ZERO_AMOUNT;
+        }
+
+        if ($this->getQtyShipped() == $this->getQtyOrdered()) {
+            return self::ZERO_AMOUNT;
+        }
+
+        $qty = $this->getQtyOrdered()/*max($this->getQtyOrdered(), $this->getQtyInvoiced())*/ - $this->getQtyShipped() - $this->getQtyCanceled(); // standard flow
+
+        // we have to ship only the items that are not refunded and not shipped
+        if ($this->getQtyRefunded() > $this->getQtyShipped()) {
+            $qty -= $this->getQtyRefunded() - $this->getQtyShipped();
+        }
+
         return max(round($qty, 8), 0);
     }
 

app/code/Magento/Sales/Model/ResourceModel/Order/Handler/State.php

@@ -6,6 +6,7 @@
 
 namespace Magento\Sales\Model\ResourceModel\Order\Handler;
 
+use Magento\Catalog\Model\Product\Type;
 use Magento\Sales\Model\Order;
 
 /**
@@ -60,13 +61,30 @@ public function isPartiallyRefundedOrderShipped(Order $order): bool
     {
         $isPartiallyRefundedOrderShipped = false;
         if ($this->getShippedItems($order) > 0
-            && $order->getTotalQtyOrdered() <= $this->getRefundedItems($order) + $this->getShippedItems($order)) {
+            && $this->getQtyItemsToShip($order) <= $this->getRefundedItems($order) + $this->getShippedItems($order)) {
             $isPartiallyRefundedOrderShipped = true;
         }
 
         return $isPartiallyRefundedOrderShipped;
     }
 
+    /**
+     * Get all refunded items number
+     *
+     * @param Order $order
+     * @return int
+     */
+    private function getQtyItemsToShip(Order $order): int
+    {
+        $numOfItemsToShip = 0;
+        foreach ($order->getAllItems() as $item) {
+            if ($item->getProductType() == Type::TYPE_SIMPLE) { // only simple products are accountable for the order qty
+                $numOfItemsToShip += (int)$item->getQtyOrdered();
+            }
+        }
+        return $numOfItemsToShip;
+    }
+
     /**
      * Get all refunded items number
      *

app/code/Magento/Sales/Test/Unit/Model/Order/ItemTest.php

@@ -323,6 +323,13 @@ public function getItemQtyVariants()
                 ],
                 'expectedResult' => ['to_ship' => 7.0, 'to_invoice' => 0.0]
             ],
+            'partially_refunded_partially_shipped_refund_lower_than_ship' => [
+                'options' => [
+                    'qty_ordered' => 12, 'qty_invoiced' => 12, 'qty_refunded' => 2, 'qty_shipped' => 4,
+                    'qty_canceled' => 0
+                ],
+                'expectedResult' => ['to_ship' => 8.0, 'to_invoice' => 0.0]
+            ],
             'complete' => [
                 'options' => [
                     'qty_ordered' => 12, 'qty_invoiced' => 12, 'qty_refunded' => 0, 'qty_shipped' => 12,
@@ -350,7 +357,8 @@ public function getItemQtyVariants()
                     'qty_canceled' => 0.4
                 ],
                 'expectedResult' => ['to_ship' => 0.0, 'to_invoice' => 0.0]
-            ]
+            ],
+
         ];
     }
 

dev/tests/integration/testsuite/Magento/Sales/Model/OrderTest.php

@@ -8,6 +8,7 @@
 namespace Magento\Sales\Model;
 
 use Magento\Catalog\Test\Fixture\Product as ProductFixture;
+use Magento\Catalog\Test\Fixture\Virtual as ProductVirtualFixture;
 use Magento\Checkout\Test\Fixture\PlaceOrder as PlaceOrderFixture;
 use Magento\Checkout\Test\Fixture\SetBillingAddress as SetBillingAddressFixture;
 use Magento\Checkout\Test\Fixture\SetDeliveryMethod as SetDeliveryMethodFixture;
@@ -18,6 +19,7 @@
 use Magento\Quote\Test\Fixture\GuestCart as GuestCartFixture;
 use Magento\Sales\Test\Fixture\Creditmemo as CreditmemoFixture;
 use Magento\Sales\Test\Fixture\Invoice as InvoiceFixture;
+use Magento\Sales\Test\Fixture\Shipment as ShipmentFixture;
 use Magento\SalesRule\Model\Rule;
 use Magento\SalesRule\Test\Fixture\Rule as RuleFixture;
 use Magento\TestFramework\Fixture\Config as Config;
@@ -90,4 +92,66 @@ public function testMultipleCreditmemosForZeroTotalOrder()
             'Should be possible to create second credit memo for zero total order if not all items are refunded yet'
         );
     }
+
+    /**
+     * Tests that an order with mixed product types in cart and with physical items either shipped or refunded cannot be shipped
+     */
+    #[
+        Config('carriers/freeshipping/active', '1', 'store', 'default'),
+        Config('payment/free/active', '1', 'store', 'default'),
+        DataFixture(ProductFixture::class, as: 'product'),
+        DataFixture(ProductVirtualFixture::class, as: 'virtual'),
+        DataFixture(GuestCartFixture::class, as: 'cart'),
+        DataFixture(
+            RuleFixture::class,
+            [
+                'simple_action' => Rule::BY_PERCENT_ACTION,
+                'discount_amount' => 100,
+                'apply_to_shipping' => 0,
+                'stop_rules_processing' => 0,
+                'sort_order' => 1,
+            ]
+        ),
+        DataFixture(
+            AddProductToCartFixture::class,
+            ['cart_id' => '$cart.id$', 'product_id' => '$product.id$', 'qty' => 2]
+        ),
+        DataFixture(
+            AddProductToCartFixture::class,
+            ['cart_id' => '$cart.id$', 'product_id' => '$virtual.id$', 'qty' => 2]
+        ),
+        DataFixture(SetBillingAddressFixture::class, ['cart_id' => '$cart.id$']),
+        DataFixture(SetShippingAddressFixture::class, ['cart_id' => '$cart.id$']),
+        DataFixture(SetGuestEmailFixture::class, ['cart_id' => '$cart.id$']),
+        DataFixture(
+            SetDeliveryMethodFixture::class,
+            ['cart_id' => '$cart.id$', 'carrier_code' => 'freeshipping', 'method_code' => 'freeshipping']
+        ),
+        DataFixture(SetPaymentMethodFixture::class, ['cart_id' => '$cart.id$', 'method' => 'free']),
+        DataFixture(PlaceOrderFixture::class, ['cart_id' => '$cart.id$'], 'order'),
+        DataFixture(InvoiceFixture::class, ['order_id' => '$order.id$'], 'invoice'),
+        DataFixture(
+            CreditmemoFixture::class,
+            ['order_id' => '$order.id$', 'items' => [['qty' => 1, 'product_id' => '$product.id$']]],
+            'creditmemo'
+        ),
+        DataFixture(
+            ShipmentFixture::class,
+            ['order_id' => '$order.id$', 'items' => [['qty' => 1, 'product_id' => '$product.id$']]],
+            'shipment'
+        )
+    ]
+    public function testOrderWithPartialShipmentAndPartialRefundAndMixedCartItems()
+    {
+        $order = $this->fixtures->get('order');
+        $this->assertFalse(
+            $order->canShip(),
+            'All items are shipped or refunded or virtual'
+        );
+        $this->assertEquals(
+            Order::STATE_COMPLETE,
+            $order->getStatus()
+        );
+    }
 }
+