>> I have a USB stick with a crucial file on it (and only an old backup
>> elsewhere).  It's formatted NTFS because I wanted to be able to open
>> the file on various Gentoo systems and my research indicated that NTFS
>> was the best solution.
>>
>> I decided to copy a 10GB file from a USB hard disk directly to the USB
>> stick this morning and I ran into errors so I canceled the operation
>> and now the file manager (thunar) has been stuck for well over an hour
>> and I'm getting errors like these over and over:
>>
>> [ 2794.535814] Buffer I/O error on dev sdc1, logical block 2134893,
>> lost async page write
>> [ 2794.535819] Buffer I/O error on dev sdc1, logical block 2134894,
>> lost async page write
>> [ 2794.535822] Buffer I/O error on dev sdc1, logical block 2134895,
>> lost async page write
>> [ 2794.535824] Buffer I/O error on dev sdc1, logical block 2134896,
>> lost async page write
>> [ 2794.535826] Buffer I/O error on dev sdc1, logical block 2134897,
>> lost async page write
>> [ 2794.535828] Buffer I/O error on dev sdc1, logical block 2134898,
>> lost async page write
>> [ 2794.535830] Buffer I/O error on dev sdc1, logical block 2134899,
>> lost async page write
>> [ 2794.535832] Buffer I/O error on dev sdc1, logical block 2134900,
>> lost async page write
>> [ 2794.535835] Buffer I/O error on dev sdc1, logical block 2134901,
>> lost async page write
>> [ 2794.535837] Buffer I/O error on dev sdc1, logical block 2134902,
>> lost async page write
>> [ 2842.568843] sd 9:0:0:0: [sdc] tag#0 FAILED Result:
>> hostbyte=DID_ERROR driverbyte=DRIVER_SENSE
>> [ 2842.568849] sd 9:0:0:0: [sdc] tag#0 Sense Key : Hardware Error [current]
>> [ 2842.568852] sd 9:0:0:0: [sdc] tag#0 Add. Sense: No additional sense
>> information
>> [ 2842.568857] sd 9:0:0:0: [sdc] tag#0 CDB: Write(10) 2a 00 01 04 a4
>> 58 00 00 f0 00
>> [ 2842.568859] blk_update_request: I/O error, dev sdc, sector 17081432
>> [ 2842.568862] buffer_io_error: 20 callbacks suppressed
>>
>> nmon says sdc is 100% busy but doesn't show any reading or writing.  I
>> once pulled the USB stick in a situation like this and I ended up
>> having to reformat it which I need to avoid this time since the file
>> is crucial.  What should I do?
>>
>> - Grant
>
> Whatever you do, do NOT try to unplug the USB you were writing to unless you
> first manage to successfully unmount it.  If you do pull the USB stick
> regardless of its current I/O state you will likely corrupt whatever file you
> were writing onto, or potentially more.
>
> You could well have a hardware failure here, which manifested itself during
> your copying operation.  Things you could try:
>
> Run lsof to find out which process is trying to access the USB fs and kill it.
> Then see if you can remount it read-only.
>
> Run dd, dcfldd, ddrescue to make an image of the complete USB stick on your
> hard drive and then try to recover any lost files with testdisk.
>
> Use any low level recovery tools the manufacturer may offer - they will likely
> require MSWindows.
>
> Shut down your OS and disconnect the USB stick, then reboot and try again to
> access it, although I would first create an image of the device using any of
> the above tools.


dd errored and lsof returned no output at all so I tried to reboot but
even that hung after the first 2 lines of output so I did a hard reset
after waiting an hour or so.  Once it came back up I tried to do 'dd
if=/dev/sdb1 of=usbstick' but I got this after awhile:

dd: error reading ‘/dev/sdb1’: Input/output error
16937216+0 records in
16937216+0 records out
8671854592 bytes (8.7 GB) copied, 230.107 s, 37.7 MB/s

It's a 64GB USB stick.  dmesg says:

[  744.729873] sd 8:0:0:0: [sdb] tag#0 FAILED Result: hostbyte=DID_OK
driverbyte=DRIVER_SENSE
[  744.729879] sd 8:0:0:0: [sdb] tag#0 Sense Key : Medium Error [current]
[  744.729883] sd 8:0:0:0: [sdb] tag#0 Add. Sense: Unrecovered read error
[  744.729886] sd 8:0:0:0: [sdb] tag#0 CDB: Read(10) 28 00 01 02 78 e0
00 00 f0 00
[  744.729889] blk_update_request: critical medium error, dev sdb,
sector 16939232
[  744.763468] sd 8:0:0:0: [sdb] tag#0 FAILED Result: hostbyte=DID_OK
driverbyte=DRIVER_SENSE
[  744.763472] sd 8:0:0:0: [sdb] tag#0 Sense Key : Medium Error [current]
[  744.763474] sd 8:0:0:0: [sdb] tag#0 Add. Sense: Unrecovered read error
[  744.763478] sd 8:0:0:0: [sdb] tag#0 CDB: Read(10) 28 00 01 02 79 00
00 00 04 00
[  744.763480] blk_update_request: critical medium error, dev sdb,
sector 16939264
[  744.763482] Buffer I/O error on dev sdb1, logical block 4234304,
async page read
[  744.786743] sd 8:0:0:0: [sdb] tag#0 FAILED Result: hostbyte=DID_OK
driverbyte=DRIVER_SENSE
[  744.786747] sd 8:0:0:0: [sdb] tag#0 Sense Key : Medium Error [current]
[  744.786750] sd 8:0:0:0: [sdb] tag#0 Add. Sense: Unrecovered read error
[  744.786753] sd 8:0:0:0: [sdb] tag#0 CDB: Read(10) 28 00 01 02 79 04
00 00 04 00
[  744.786755] blk_update_request: critical medium error, dev sdb,
sector 16939268
[  744.786758] Buffer I/O error on dev sdb1, logical block 4234305,
async page read

I haven't tried to mount it yet.  Any suggestions?

- Grant

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