Replace mdadm
From Karmaking
1. Mark faulty drive as "failed":
mdadm --fail /dev/md1 /dev/sdb1
2. Remove drive:
mdadm --remove /dev/md1 /dev/sdb1
3. Copy partition table:
sfdisk -d /dev/sda | sfdisk /dev/sdb
4. Add new partitions to arrays:
mdadm --add /dev/md1 /dev/sdb1