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In this example:

md0
sda = failed/replaced
sdb = working

 

"Fail and remove drive from Raid"
mdadm /dev/md0 --fail /dev/sda1 --remove /dev/sda1 

 

Insert new disk and copy partition table from original disk.

sfdisk -d /dev/sdb | sfdisk /dev/sda 

 

Does it show under blkid? Is the disk brand new? Partition it with ext4?

sudo mkfs.ext4 /dev/sda1 

 

Add new disk back to mdadm

mdadm --add /dev/md0 /dev/sda1 

 

check status

sudo mdadm --detail /dev/md0 

 

check that its rebuilding

cat /proc/mdstat
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