A (more or less wild) guess why this misreporting may not have surfaced
with any bad effects before:

After booting manually and reassembling the array manually I noticed the
usb disk did fail after a while and was dropped from the array, so it
has become unreliably.

So maybe it is this condition on boot (usb disk was droped from the
array) where the array is not run yet (possibly waiting for the disk now
having a different device name) and cryptsetup grabs the raid_member
instead of waiting for the array.

-- 
blkid reports root raid_member (on usb) as luks, which is booted while raid 
remains "inactive"
https://bugs.launchpad.net/bugs/531240
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