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My RAID1 array is currently running with 3 disks (2x6TB and 1x3TB). I want to remove the smaller disk and wonder if it makes sense to put it in the safe as cold backup. The idea is to be able to mount it as degraded RAID1 array, independent of the running RAID.

Question 1: Should I set the disk to faulty before removing it?

Question 2: Will I be able to mount the backup disk on the same device where the RAID is running or will mdadm detect the disk to belong to the array already there?

Linux kernel is 6.8.0, mdadm is v4.3.

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After removing the drive from the array you should wipe the MD superblock with wipefs. After that it will not make a difference whether you set the drive to faulty before as this information is then lost anyway.

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