It's common problem you will have to deal with when you replace a disk in a Linux software array. The first step is always to prepart the partition table after you replaced the bad disk.
Here is just a quick steps:
Copy the partition created by fdisk
Copy the partition table from sda --> sdb
sfdisk -d /dev/sda | sfdisk /dev/sdb
copy the partition table created by parted
Copy the partition table from sda --> sdb
sgdisk -R /dev/sdb /dev/sda # copy sda partition table to sdb
sgdisk -G /dev/sdb # Randomizes the GUID on the disk and all the partitions
Note: not like sfdisk, the disk sda is the disk you want to copy the partition table from.
sgdisk is in the gdisk package which is available in most of linux distributions.
That's it!
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