I'm digging into this some more and it seems that mdadm in Ubuntu 12.04 is detecting an old unused superblock on /dev/sdb that mdadm in Ubuntu 10.04 ignored.
$ mdadm --examine --scan --verbose ARRAY /dev/md1 level=raid1 num-devices=2 UUID=5fb6928e:89f09cde:d0aebb6f:e3c24c31 spares=1 devices=/dev/sdb ARRAY /dev/md0 level=raid1 num-devices=2 UUID=a4176cee:096f0ba6:40663db4:2b8b6d2c devices=/dev/sdc1,/dev/sdb1
When we examine /dev/sdb, we see there's an old superblock there (note the update date is Thu Jul 7 09:00:21 2011).
$ mdadm --examine /dev/sdb /dev/sdb: Magic : a92b4efc Version : 0.90.00 UUID : 5fb6928e:89f09cde:d0aebb6f:e3c24c31 Creation Time : Fri Jul 1 10:00:58 2011 Raid Level : raid1 Used Dev Size : 1953513408 (1863.02 GiB 2000.40 GB) Array Size : 1953513408 (1863.02 GiB 2000.40 GB) Raid Devices : 2 Total Devices : 2 Preferred Minor : 1
Update Time : Thu Jul 7 09:00:21 2011 State : clean Active Devices : 1 Working Devices : 2 Failed Devices : 1 Spare Devices : 1 Checksum : 57d747d3 - correct Events : 24
Number Major Minor RaidDevice State this 2 8 16 2 spare /dev/sdb
0 0 8 33 0 active sync /dev/sdc1 1 1 0 0 1 faulty removed 2 2 8 16 2 spare /dev/sdb
I'm digging into this some more and it seems that mdadm in Ubuntu 12.04 is detecting an old unused superblock on /dev/sdb that mdadm in Ubuntu 10.04 ignored.
$ mdadm --examine --scan --verbose 89f09cde: d0aebb6f: e3c24c31 096f0ba6: 40663db4: 2b8b6d2c /dev/sdc1, /dev/sdb1
ARRAY /dev/md1 level=raid1 num-devices=2 UUID=5fb6928e:
spares=1 devices=/dev/sdb
ARRAY /dev/md0 level=raid1 num-devices=2 UUID=a4176cee:
devices=
When we examine /dev/sdb, we see there's an old superblock there (note the update date is Thu Jul 7 09:00:21 2011).
$ mdadm --examine /dev/sdb 89f09cde: d0aebb6f: e3c24c31
/dev/sdb:
Magic : a92b4efc
Version : 0.90.00
UUID : 5fb6928e:
Creation Time : Fri Jul 1 10:00:58 2011
Raid Level : raid1
Used Dev Size : 1953513408 (1863.02 GiB 2000.40 GB)
Array Size : 1953513408 (1863.02 GiB 2000.40 GB)
Raid Devices : 2
Total Devices : 2
Preferred Minor : 1
Update Time : Thu Jul 7 09:00:21 2011
State : clean
Active Devices : 1
Working Devices : 2
Failed Devices : 1
Spare Devices : 1
Checksum : 57d747d3 - correct
Events : 24
Number Major Minor RaidDevice State
this 2 8 16 2 spare /dev/sdb
0 0 8 33 0 active sync /dev/sdc1
1 1 0 0 1 faulty removed
2 2 8 16 2 spare /dev/sdb