> the problem is that the second disk is automatically added back into
the array by mdadm --increment. Once the disk has been marked as removed
from the array, it should require manual intervention to put it back.

In the case at hand mdadm should not only refuse addition due to it
being "removed". Even if you add the disks manually mdadm should not
just sync the disk slower to appear to the first one, because the parts
are inconsistent!

I think a nice solution to detect this (counter+random) may have been
posted to the linux-raid list.

The data corruption comes from the inconsistent parts (conflicting
changes) that should require conscious user intervention or maybe
configuration to decide about the sync direction.

Not auto re-adding manually removed raid_members, is a usability
decision, that could probably made configurable but I see unrelated to
the data corruption.

-- 
booting out of sync RAID1 array fails with ext3 (comes up as already in sync)
https://bugs.launchpad.net/bugs/557429
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