> I believe this should fail and refuse to use the second disk until you
manually re-add it to the array, causing a full resync.

Yes, if there is a way for mdadm to determine if members are out of sync
it should fail on conflicting updates that occured on separated parts of
the array (as is the case here).

It should not fail if a usable remaining part of an array has been
updated and the removed disk is plugged in again unchanged (hotplug
readding of a raid member that is used as a backup).

It should never sync depending on device order (since that is rather
random in hotplug systems anyway).

-- 
booting out of sync RAID1 array fails with ext3 (comes up as already in sync)
https://bugs.launchpad.net/bugs/557429
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