Help formating a 4Kn harddrive to ext4

[lyoth]

I am running ubuntu 20.04 and I keep getting error when trying to format a 4kn harddrive to ext4.
Harddrive is HUH721010AL4200, I verified the 3 drives I have smart check are good, no badblocks, or any ecc errors.
I tested formatting with xfs and zfs and it works fine.
With ext4 I keep getting this error, and the disk get disconnect, and I either need to eject the disk and insert it back in, or power down and power up.

$ sudo mkfs.ext4 -b 4096 /dev/sdb
mke2fs 1.45.5 (07-Jan-2020)
Found a gpt partition table in /dev/sdb
Proceed anyway? (y,N) y
Creating filesystem with 2441609216 4k blocks and 305201152 inodes
Filesystem UUID: a140df14-ee29-4312-8478-22f17f509ae3
Superblock backups stored on blocks:
32768, 98304, 163840, 229376, 294912, 819200, 884736, 1605632, 2654208,
4096000, 7962624, 11239424, 20480000, 23887872, 71663616, 78675968,
102400000, 214990848, 512000000, 550731776, 644972544, 1934917632

Allocating group tables: done
Writing inode tables: done
Creating journal (262144 blocks): done
Writing superblocks and filesystem accounting information: mkfs.ext4: Input/output error while writing out and closing file system

this is from dmesg

[  431.487576] sd 0:0:1:0: device_block, handle(0x000b)
[  433.487585] sd 0:0:1:0: device_unblock and setting to running, handle(0x000b)
[  433.501158] sd 0:0:1:0: Power-on or device reset occurred
[  442.888750] mpt3sas_cm0: log_info(0x31120101): originator(PL), code(0x12), sub_code(0x0101)
[  442.888755] mpt3sas_cm0: log_info(0x31120101): originator(PL), code(0x12), sub_code(0x0101)
[  442.888783] sd 0:0:1:0: [sdb] tag#1221 FAILED Result: hostbyte=DID_SOFT_ERROR driverbyte=DRIVER_OK
[  442.888790] sd 0:0:1:0: [sdb] tag#1221 CDB: Read(10) 28 00 91 87 ff f0 00 00 01 00
[  442.888794] print_req_error: 1 callbacks suppressed
[  442.888800] blk_update_request: I/O error, dev sdb, sector 19532873600 op 0x0:(READ) flags 0x80700 phys_seg 1 prio class 0
[  442.888820] sd 0:0:1:0: [sdb] tag#1220 FAILED Result: hostbyte=DID_SOFT_ERROR driverbyte=DRIVER_OK
[  442.888825] sd 0:0:1:0: [sdb] tag#1220 CDB: Write same(16) 93 00 00 00 00 00 91 87 ff f0 00 00 00 10 00 00
[  442.888830] blk_update_request: I/O error, dev sdb, sector 19532873600 op 0x9:(WRITE_ZEROES) flags 0x1000800 phys_seg 0 prio class 0
[  443.240264] sd 0:0:1:0: device_block, handle(0x000b)
[  444.987288] sd 0:0:1:0: device_unblock and setting to running, handle(0x000b)
[  444.996899] blk_update_request: I/O error, dev sdb, sector 19532873600 op 0x0:(READ) flags 0x0 phys_seg 1 prio class 0
[  444.996907] buffer_io_error: 267852 callbacks suppressed
[  444.996909] Buffer I/O error on dev sdb, logical block 2441609200, async page read
[  444.996927] blk_update_request: I/O error, dev sdb, sector 19532873600 op 0x1:(WRITE) flags 0x800 phys_seg 16 prio class 0
[  444.996940] blk_update_request: I/O error, dev sdb, sector 0 op 0x1:(WRITE) flags 0x800 phys_seg 1 prio class 0
[  444.996943] Buffer I/O error on dev sdb, logical block 0, lost async page write
[  444.997045] blk_update_request: I/O error, dev sdb, sector 19532873600 op 0x9:(WRITE_ZEROES) flags 0x800 phys_seg 0 prio class 0
[  444.997326] blk_update_request: I/O error, dev sdb, sector 16648 op 0x9:(WRITE_ZEROES) flags 0x1000800 phys_seg 0 prio class 0
[  444.997422] blk_update_request: I/O error, dev sdb, sector 16648 op 0x1:(WRITE) flags 0x800 phys_seg 1 prio class 0
[  445.141591] mpt3sas_cm0: mpt3sas_transport_port_remove: removed: sas_addr(0x5000cca2567bae71)
[  445.141595] mpt3sas_cm0: removing handle(0x000b), sas_addr(0x5000cca2567bae71)
[  445.141597] mpt3sas_cm0: enclosure logical id(0x5003048017fa043f), slot(5)
[  445.141598] mpt3sas_cm0: enclosure level(0x0000), connector name(     )
[  445.431806] Buffer I/O error on dev sdb, logical block 1, lost async page write
[  445.431812] Buffer I/O error on dev sdb, logical block 2, lost async page write
[  445.431814] Buffer I/O error on dev sdb, logical block 3, lost async page write
[  445.431816] Buffer I/O error on dev sdb, logical block 4, lost async page write
[  445.431818] Buffer I/O error on dev sdb, logical block 5, lost async page write
[  445.431819] Buffer I/O error on dev sdb, logical block 6, lost async page write
[  445.431821] Buffer I/O error on dev sdb, logical block 7, lost async page write
[  445.431823] Buffer I/O error on dev sdb, logical block 8, lost async page write

Any help would be appreciated, I have been trying for 3 days now and no progress on ext4.

 

[RTM]

First of all, I would start by creating a partition that covers the entire disk with gdisk.
It should be as simple as:
sudo gdisk /dev/sdb
<p> (OPTIONAL: shows information about disk sector size)
<o> (to clear existing information)
<n> (and then press enter until it has no more questions to accept default settings)
<w> (to save)

Then I would rerun mkfs.ext4 on the partition:
sudo mkfs.ext4 /dev/sdb1 (note I would omit the -b flag)

That all said, it kind of looks like a firmware issue on the SAS controller, it is my understanding that some of the older ones in RAID (IR) mode do not like 4k drives (though there is probably more to it than that). So... you may want to look if there is an updated firmware for the SAS controller.