Directory creation failure and no errors - powershell

Question

I made a function and I thought it worked well. In my primary script I am importing the function and then calling it. The idea of the function is simply to make a filename with a path.
At the end of the function I added a portion that would check if the directory exists and if not create it.
Here are the problems.
I get no errors.
The directory is not always created`.
When the primary script runs and attempts to export the csv it doesn't because the directory doesn't exist.
3a) if I create the directory everything works.
The folder it tries to create is "C:\Reports" but I am an admin on the computer and I understand it should be in special folders. I suppose I can force that if you folks want. But I would think I would get an error if the directory could not create as written below.
Portion of the function that should be working.
$ProcessError = $null
IF (!(test-path $DirectoryName)) {
New-Item -Path $DirectoryName -ItemType Directory -ErrorAction SilentlyContinue -ErrorVariable ProcessError -Force
If ($ProcessError) {
Write-Warning "Problem trying to create $DirectoryName."
}
Return [string]$FullPath
}
This is the primary call to the function and what is strange is I get no error here as well in section 2 primary below!!
section 1 primary
If ($SimChange -eq $True) {
$ResultFileName = MRNAP -ReportName "ExampleGoogleLicenseReport" -Move -JustDate
}
Else {
$ResultFileName = MRNAP -ReportName "GoogleLicenseReport" -Move -JustDate
}
Section 2 primary
$ProcessError = $null
$Results | Export-Csv $ResultFileName -NoTypeInformation -ErrorVariable ProcessError -ErrorAction SilentlyContinue
If ($ProcessError) {
Write-Warning "Unable to save report output to $ResultFileName"
}
url to function that creates the filename.
https://github.com/dcazman/MRNAP/blob/main/MRNAP.ps1
I find this all very frustrating and Section 2 primary above. Should be giving me that warning as written....I thought.

Answer 1

In the comments there is chat about a bug and using try catch. Additionally, we have talked about this problem on stack before with
Create directory if it does not exist
and
Function return value in PowerShell
What I did for now that works.
IF (!(test-path $DirectoryName)) {
$Dircreate = New-Item -ItemType Directory -Force -Path $($DirectoryName.Substring(0, 3)) -Name $($DirectoryName.Substring(3)) -ErrorAction SilentlyContinue -ErrorVariable ProcessError | Out-Null
If ($ProcessError) {
Write-Warning "Problem trying to create $DirectoryName."
[bool]$Created = $False
}
Else {
[bool]$Created = $true
}
}
If ($Created) {
If ($FullPath -as [string]) {
Return [string]$FullPath
}
Else {
Return [string]$FullPath[1]
}
}
This above doesn't use a try catch but I will give that a shot later.
For some bug reason creating the directory was changing $fullpath from a string to an array and that is why the test above works using the -as [string]