Portable Hard Drives - Integrity and Failure

Integrity and Failure

Due to the extremely close spacing between the heads and the disk surface, HDDs are vulnerable to being damaged by a head crash—a failure of the disk in which the head scrapes across the platter surface, often grinding away the thin magnetic film and causing data loss. Head crashes can be caused by electronic failure, a sudden power failure, physical shock, contamination of the drive's internal enclosure, wear and tear, corrosion, or poorly manufactured platters and heads.

The HDD's spindle system relies on air pressure inside the disk enclosure to support the heads at their proper flying height while the disk rotates. HDDs require a certain range of air pressures in order to operate properly. The connection to the external environment and pressure occurs through a small hole in the enclosure (about 0.5 mm in breadth), usually with a filter on the inside (the breather filter). If the air pressure is too low, then there is not enough lift for the flying head, so the head gets too close to the disk, and there is a risk of head crashes and data loss. Specially manufactured sealed and pressurized disks are needed for reliable high-altitude operation, above about 3,000 m (9,800 ft). Modern disks include temperature sensors and adjust their operation to the operating environment. Breather holes can be seen on all disk drives—they usually have a sticker next to them, warning the user not to cover the holes. The air inside the operating drive is constantly moving too, being swept in motion by friction with the spinning platters. This air passes through an internal recirculation (or "recirc") filter to remove any leftover contaminants from manufacture, any particles or chemicals that may have somehow entered the enclosure, and any particles or outgassing generated internally in normal operation. Very high humidity for extended periods can corrode the heads and platters.

For giant magnetoresistive (GMR) heads in particular, a minor head crash from contamination (that does not remove the magnetic surface of the disk) still results in the head temporarily overheating, due to friction with the disk surface, and can render the data unreadable for a short period until the head temperature stabilizes (so called "thermal asperity", a problem which can partially be dealt with by proper electronic filtering of the read signal).

When a mechanical hard disk requires repairs, the easiest method is to replace the circuit board using an identical hard disk, provided it is the circuit board that has malfunctioned. In the case of read-write head faults, they can be replaced using specialized tools in a dust-free environment. If the disk platters are undamaged, they can be transferred into an identical enclosure and the data can be copied or cloned onto a new drive. In the event of disk-platter failures, disassembly and imaging of the disk platters may be required. For logical damage to file systems, a variety of tools, including fsck on UNIX-like systems and CHKDSK on Windows, can be used for data recovery. Recovery from logical damage can require file carving.

A 2011 summary of research into SSD and magnetic disk failure patterns by Tom's Hardware summarized research findings as follows:

1. MTBF does not indicate reliability; the annualized failure rate is higher and usually more relevant.
2. Magnetic disks do not have a specific tendency to fail during early use, and temperature only has a minor effect; instead, failure rates steadily increase with age.
3. SMART warns of mechanical issues but not other issues affecting reliability, and is therefore not a reliable indicator of condition.
4. Failure rates of drives sold as "enterprise" and "consumer" are "very much similar", although customized for their different environments.
5. In drive arrays, one drive's failure significantly increases the short-term chance of a second drive failing.