I'm not certain if I'm having the same trouble as you, but mdadm fell
over pretty hard for me on 2.6.24-16-server, mdadm - v2.6.3 - 20th
August 2007 when expanding 5x500GB -> 6x500GB. I lost all the data on
the raid (oops).
Possibly this is a bug in sata_sil with lots of disk writes? 5 of the 6
disks were on siI 3512 based SATA cards (The other was an onboard mobo
SATA port). Similarly, I can write to the disks individually fine, they
check out okay with badblocks and smartctl.

Did you get any weirdness in dmesg? I had a couple of odd things about
the SATA link going down... so possibly unrelated.

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mdadm, Raid5 and XFS stuck in uninterruptable sleep
https://bugs.launchpad.net/bugs/208551
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