Have you tried updating your bios yet?  I also notice that the version
recorded in the signature is rather old.

According to Intel, the metadata is supposed to reside in the last two
sectors of the disk.  Based on the incorrect position and the incorrect
disk size I noted that was recorded before, it appears that your bios
has a bug where it sometimes can not correctly determine the size of
that disk.

I have a suspicion that the bios may be issuing commands to hide the
tail end of the one disk, which the Linux kernel resets, causing the
metadata to appear in the wrong position and the bios and windows don't
recognize the disk after a warm boot because it does not reapply the
hide command.

Another strange thing is that originally the signature was in the
correct place and dmraid found it, but the disks did not agree on the
size.  What changed between the time you originally created the array,
and when you recreated it with the signature now in the wrong place?
Odd.

-- 
ich9R raid array not detected
https://bugs.launchpad.net/bugs/219393
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