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Format external hard drive with I/O errors

us flag

I'm trying to format an external HDD that has known bad sectors. I was able to recover most of the data using ddrescue. Now I want to completely wipe the HDD. However, I keep getting I/O errors and the partitions no longer exist.

Question: given the following information, is there any chance that the HDD can be formatted and re-used? This HDD will be used as a file transfer station so data loss is not an issue.

This HDD is listed as sdc:

NAME   MAJ:MIN RM   SIZE RO TYPE MOUNTPOINT
loop0    7:0    0  99.4M  1 loop /snap/core/11993
loop1    7:1    0 110.5M  1 loop /snap/core/12603
loop2    7:2    0  55.5M  1 loop /snap/core18/2253
loop3    7:3    0  55.5M  1 loop /snap/core18/2284
loop4    7:4    0  61.9M  1 loop /snap/core20/1270
loop5    7:5    0  61.9M  1 loop /snap/core20/1328
loop6    7:6    0  67.2M  1 loop /snap/lxd/21835
loop7    7:7    0  19.8M  1 loop /snap/minidlna-escoand/19
loop8    7:8    0  68.3M  1 loop /snap/powershell/194
loop9    7:9    0  68.1M  1 loop /snap/powershell/196
sda      8:0    0 298.1G  0 disk
├─sda1   8:1    0   512M  0 part /mnt/localServer01
└─sda2   8:2    0 297.6G  0 part /
sdb      8:16   0   1.8T  0 disk
└─sdb1   8:17   0   1.8T  0 part
sdc      8:32   0 698.7G  0 disk
sr0     11:0    1  1024M  0 rom

dd returns I/O error when I tried formatting the disk:

sudo dd if=/dev/zero of=/dev/sdc
dd: writing to '/dev/sdc': Input/output error
1+0 records in
0+0 records out
0 bytes copied, 184.335 s, 0.0 kB/s

dmesg also shows I/O error:

[144465.457953] blk_update_request: I/O error, dev sdc, sector 0 op 0x0:(READ) flags 0x0 phys_seg 1 prio class 0
[144465.462738] Buffer I/O error on dev sdc, logical block 0, async page read
[147350.634452] sd 6:0:0:1: [sdc] tag#7 uas_eh_abort_handler 0 uas-tag 1 inflight: CMD IN
[147350.634464] sd 6:0:0:1: [sdc] tag#7 CDB: Read(10) 28 00 00 00 00 00 00 00 08 00
[147389.549614] sd 6:0:0:1: [sdc] tag#4 uas_zap_pending 0 uas-tag 1 inflight: CMD
[147389.549624] sd 6:0:0:1: [sdc] tag#4 CDB: Read(10) 28 00 00 00 00 00 00 00 08 00
[147420.268875] sd 6:0:0:1: [sdc] tag#5 uas_zap_pending 0 uas-tag 1 inflight: CMD
[147420.268885] sd 6:0:0:1: [sdc] tag#5 CDB: Read(10) 28 00 00 00 00 00 00 00 08 00
[147450.988273] sd 6:0:0:1: [sdc] tag#6 uas_zap_pending 0 uas-tag 1 inflight: CMD
[147450.988282] sd 6:0:0:1: [sdc] tag#6 CDB: Read(10) 28 00 00 00 00 00 00 00 08 00
[147481.707378] sd 6:0:0:1: [sdc] tag#7 uas_zap_pending 0 uas-tag 1 inflight: CMD
[147481.707387] sd 6:0:0:1: [sdc] tag#7 CDB: Read(10) 28 00 00 00 00 00 00 00 08 00
[147512.426775] sd 6:0:0:1: [sdc] tag#4 uas_zap_pending 0 uas-tag 1 inflight: CMD
[147512.426784] sd 6:0:0:1: [sdc] tag#4 CDB: Read(10) 28 00 00 00 00 00 00 00 08 00
[147512.751588] sd 6:0:0:1: [sdc] tag#4 FAILED Result: hostbyte=DID_RESET driverbyte=DRIVER_OK
[147512.751598] sd 6:0:0:1: [sdc] tag#4 CDB: Read(10) 28 00 00 00 00 00 00 00 08 00

smartctl -x /dev/sdc shows that the HDD has been ON for 9915 hours:

=== START OF INFORMATION SECTION ===
Model Family:     HGST Travelstar 5K1000
Device Model:     HGST HTS541075A9E680
Serial Number:    J8120077G9WM0A
LU WWN Device Id: 5 000cca 69ac47eff
Firmware Version: JA2OA560
User Capacity:    750,156,374,016 bytes [750 GB]
Sector Sizes:     512 bytes logical, 4096 bytes physical
Rotation Rate:    5400 rpm
Form Factor:      2.5 inches
Device is:        In smartctl database [for details use: -P show]
ATA Version is:   ATA8-ACS T13/1699-D revision 6
SATA Version is:  SATA 2.6, 6.0 Gb/s (current: 6.0 Gb/s)
Local Time is:    Mon Feb  7 20:38:58 2022 UTC
SMART support is: Available - device has SMART capability.
SMART support is: Enabled
AAM feature is:   Unavailable
APM level is:     1 (minimum power consumption with standby)
Rd look-ahead is: Enabled
Write cache is:   Disabled
DSN feature is:   Unavailable
ATA Security is:  ENABLED, PW level HIGH, **LOCKED** [SEC4]
Wt Cache Reorder: Unknown (SCT not supported if ATA Security is LOCKED)

=== START OF READ SMART DATA SECTION ===
SMART Status not supported: Incomplete response, ATA output registers missing
SMART overall-health self-assessment test result: FAILED!
Drive failure expected in less than 24 hours. SAVE ALL DATA.
Warning: This result is based on an Attribute check.
See vendor-specific Attribute list for failed Attributes.

General SMART Values:
Offline data collection status:  (0x00) Offline data collection activity
                                        was never started.
                                        Auto Offline Data Collection: Disabled.
Self-test execution status:      (   0) The previous self-test routine completed
                                        without error or no self-test has ever
                                        been run.
Total time to complete Offline
data collection:                (   45) seconds.
Offline data collection
capabilities:                    (0x5b) SMART execute Offline immediate.
                                        Auto Offline data collection on/off support.
                                        Suspend Offline collection upon new
                                        command.
                                        Offline surface scan supported.
                                        Self-test supported.
                                        No Conveyance Self-test supported.
                                        Selective Self-test supported.
SMART capabilities:            (0x0003) Saves SMART data before entering
                                        power-saving mode.
                                        Supports SMART auto save timer.
Error logging capability:        (0x01) Error logging supported.
                                        General Purpose Logging supported.
Short self-test routine
recommended polling time:        (   2) minutes.
Extended self-test routine
recommended polling time:        ( 184) minutes.
SCT capabilities:              (0x003d) SCT Status supported.
                                        SCT Error Recovery Control supported.
                                        SCT Feature Control supported.
                                        SCT Data Table supported.

SMART Attributes Data Structure revision number: 16
Vendor Specific SMART Attributes with Thresholds:
ID# ATTRIBUTE_NAME          FLAGS    VALUE WORST THRESH FAIL RAW_VALUE
  1 Raw_Read_Error_Rate     PO-R--   001   001   062    NOW  466812927
  2 Throughput_Performance  P-S---   100   100   040    -    0
  3 Spin_Up_Time            POS---   206   206   033    -    1
  4 Start_Stop_Count        -O--C-   085   085   000    -    24164
  5 Reallocated_Sector_Ct   PO--CK   001   001   005    NOW  0
  7 Seek_Error_Rate         PO-R--   100   100   067    -    0
  8 Seek_Time_Performance   P-S---   100   100   040    -    0
  9 Power_On_Hours          -O--C-   078   078   000    -    9915
 10 Spin_Retry_Count        PO--C-   100   100   060    -    0
 12 Power_Cycle_Count       -O--CK   100   100   000    -    1462
191 G-Sense_Error_Rate      -O-R--   100   100   000    -    0
192 Power-Off_Retract_Count -O--CK   100   100   000    -    49
193 Load_Cycle_Count        -O--C-   085   085   000    -    153471
194 Temperature_Celsius     -O----   230   230   000    -    26 (Min/Max 12/48)
196 Reallocated_Event_Count -O--CK   001   001   000    -    4142
197 Current_Pending_Sector  -O---K   001   001   000    -    21952
198 Offline_Uncorrectable   ---R--   100   100   000    -    0
199 UDMA_CRC_Error_Count    -O-R--   200   200   000    -    0
223 Load_Retry_Count        -O-R--   100   100   000    -    0
                            ||||||_ K auto-keep
                            |||||__ C event count
                            ||||___ R error rate
                            |||____ S speed/performance
                            ||_____ O updated online
                            |______ P prefailure warning

General Purpose Log Directory Version 1
SMART           Log Directory Version 1 [multi-sector log support]
Address    Access  R/W   Size  Description
0x00       GPL,SL  R/O      1  Log Directory
0x01           SL  R/O      1  Summary SMART error log
0x02           SL  R/O      1  Comprehensive SMART error log
0x03       GPL     R/O      1  Ext. Comprehensive SMART error log
0x06           SL  R/O      1  SMART self-test log
0x07       GPL     R/O      1  Extended self-test log
0x09           SL  R/W      1  Selective self-test log
0x10       GPL     R/O      1  NCQ Command Error log
0x11       GPL     R/O      1  SATA Phy Event Counters log
0x80-0x9f  GPL,SL  R/W     16  Host vendor specific log
0xe0       GPL,SL  R/W      1  SCT Command/Status
0xe1       GPL,SL  R/W      1  SCT Data Transfer

SMART Extended Comprehensive Error Log Version: 1 (1 sectors)
Device Error Count: 65535 (device log contains only the most recent 4 errors)
        CR     = Command Register
        FEATR  = Features Register
        COUNT  = Count (was: Sector Count) Register
        LBA_48 = Upper bytes of LBA High/Mid/Low Registers ]  ATA-8
        LH     = LBA High (was: Cylinder High) Register    ]   LBA
        LM     = LBA Mid (was: Cylinder Low) Register      ] Register
        LL     = LBA Low (was: Sector Number) Register     ]
        DV     = Device (was: Device/Head) Register
        DC     = Device Control Register
        ER     = Error register
        ST     = Status register
Powered_Up_Time is measured from power on, and printed as
DDd+hh:mm:SS.sss where DD=days, hh=hours, mm=minutes,
SS=sec, and sss=millisec. It "wraps" after 49.710 days.

Error 65535 [0] occurred at disk power-on lifetime: 8969 hours (373 days + 17 hours)
  When the command that caused the error occurred, the device was active or idle.

  After command completion occurred, registers were:
  ER -- ST COUNT  LBA_48  LH LM LL DV DC
  -- -- -- == -- == == == -- -- -- -- --
  40 -- 51 00 08 00 00 23 78 10 00 03 00  Error: UNC 8 sectors at LBA = 0x23781000 = 595070976

  Commands leading to the command that caused the error were:
  CR FEATR COUNT  LBA_48  LH LM LL DV DC  Powered_Up_Time  Command/Feature_Name
  -- == -- == -- == == == -- -- -- -- --  ---------------  --------------------
  25 00 00 00 08 00 00 23 78 10 00 40 00     00:04:40.714  READ DMA EXT
  25 00 00 01 80 00 00 54 d4 10 80 40 00     00:04:40.710  READ DMA EXT
  25 00 00 00 38 00 00 54 d4 10 40 40 00     00:04:40.709  READ DMA EXT
  25 00 00 00 18 00 00 54 d4 10 20 40 00     00:04:40.709  READ DMA EXT
  25 00 00 00 08 00 00 54 d4 10 10 40 00     00:04:40.709  READ DMA EXT

Error 65534 [3] occurred at disk power-on lifetime: 8969 hours (373 days + 17 hours)
  When the command that caused the error occurred, the device was active or idle.

  After command completion occurred, registers were:
  ER -- ST COUNT  LBA_48  LH LM LL DV DC
  -- -- -- == -- == == == -- -- -- -- --
  40 -- 51 00 08 00 00 23 78 10 00 03 00  Error: UNC 8 sectors at LBA = 0x23781000 = 595070976

  Commands leading to the command that caused the error were:
  CR FEATR COUNT  LBA_48  LH LM LL DV DC  Powered_Up_Time  Command/Feature_Name
  -- == -- == -- == == == -- -- -- -- --  ---------------  --------------------
  25 00 00 00 08 00 00 23 78 10 00 40 00     00:04:36.900  READ DMA EXT
  25 00 00 00 08 00 00 54 d4 10 78 40 00     00:04:36.899  READ DMA EXT
  25 00 00 00 08 00 00 00 89 88 00 40 00     00:04:36.876  READ DMA EXT
  25 00 00 00 08 00 00 23 0d 30 00 40 00     00:04:36.851  READ DMA EXT
  25 00 00 00 68 00 00 54 d4 0f 88 40 00     00:04:36.850  READ DMA EXT

Error 65533 [2] occurred at disk power-on lifetime: 8969 hours (373 days + 17 hours)
  When the command that caused the error occurred, the device was active or idle.

  After command completion occurred, registers were:
  ER -- ST COUNT  LBA_48  LH LM LL DV DC
  -- -- -- == -- == == == -- -- -- -- --
  40 -- 51 00 08 00 00 00 09 68 10 00 00  Error: UNC 8 sectors at LBA = 0x00096810 = 616464

  Commands leading to the command that caused the error were:
  CR FEATR COUNT  LBA_48  LH LM LL DV DC  Powered_Up_Time  Command/Feature_Name
  -- == -- == -- == == == -- -- -- -- --  ---------------  --------------------
  25 00 00 00 08 00 00 00 09 68 10 40 00     00:04:32.895  READ DMA EXT
  25 00 00 00 08 00 00 00 09 68 10 40 00     00:04:29.072  READ DMA EXT
  25 00 00 00 08 00 00 54 d4 10 18 40 00     00:04:29.052  READ DMA EXT
  25 00 00 02 00 00 00 23 0d 1c 00 40 00     00:04:29.042  READ DMA EXT
  25 00 00 00 68 00 00 23 18 0f 88 40 00     00:04:29.040  READ DMA EXT

Error 65532 [1] occurred at disk power-on lifetime: 8969 hours (373 days + 17 hours)
  When the command that caused the error occurred, the device was active or idle.

  After command completion occurred, registers were:
  ER -- ST COUNT  LBA_48  LH LM LL DV DC
  -- -- -- == -- == == == -- -- -- -- --
  40 -- 51 00 08 00 00 00 09 68 10 00 00  Error: UNC 8 sectors at LBA = 0x00096810 = 616464

  Commands leading to the command that caused the error were:
  CR FEATR COUNT  LBA_48  LH LM LL DV DC  Powered_Up_Time  Command/Feature_Name
  -- == -- == -- == == == -- -- -- -- --  ---------------  --------------------
  25 00 00 00 08 00 00 00 09 68 10 40 00     00:04:29.072  READ DMA EXT
  25 00 00 00 08 00 00 54 d4 10 18 40 00     00:04:29.052  READ DMA EXT
  25 00 00 02 00 00 00 23 0d 1c 00 40 00     00:04:29.042  READ DMA EXT
  25 00 00 00 68 00 00 23 18 0f 88 40 00     00:04:29.040  READ DMA EXT
  25 00 00 00 80 00 00 23 18 0f 00 40 00     00:04:29.039  READ DMA EXT

SMART Extended Self-test Log Version: 1 (1 sectors)
No self-tests have been logged.  [To run self-tests, use: smartctl -t]

SMART Selective self-test log data structure revision number 1
 SPAN  MIN_LBA  MAX_LBA  CURRENT_TEST_STATUS
    1        0        0  Not_testing
    2        0        0  Not_testing
    3        0        0  Not_testing
    4        0        0  Not_testing
    5        0        0  Not_testing
Selective self-test flags (0x0):
  After scanning selected spans, do NOT read-scan remainder of disk.
If Selective self-test is pending on power-up, resume after 0 minute delay.

SCT Commands not supported if ATA Security is LOCKED

Device Statistics (GP/SMART Log 0x04) not supported

Pending Defects log (GP Log 0x0c) not supported

SATA Phy Event Counters (GP Log 0x11)
ID      Size     Value  Description
0x0001  2            0  Command failed due to ICRC error
0x0002  2            0  R_ERR response for data FIS
0x0003  2            0  R_ERR response for device-to-host data FIS
0x0004  2            0  R_ERR response for host-to-device data FIS
0x0005  2            0  R_ERR response for non-data FIS
0x0006  2            0  R_ERR response for device-to-host non-data FIS
0x0007  2            0  R_ERR response for host-to-device non-data FIS
0x0009  2          457  Transition from drive PhyRdy to drive PhyNRdy
0x000a  2          456  Device-to-host register FISes sent due to a COMRESET
0x000b  2            0  CRC errors within host-to-device FIS
0x000d  2            0  Non-CRC errors within host-to-device FIS
David avatar
cn flag
The hard drive is dead time to bury it. No there is no way it is ever usable again.
Nmath avatar
ng flag
All of the information and narrative you have posted supports the hypothesis that your hard drive is failing. There is nothing you can do in Ubuntu or any other software to resurrect a dead hard drive. If the drive is failing or has failed, you will need to replace it.
mangohost

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