We can probably frame an answer better if we know what setup you have now running the RAID 10. Is it like Linux RAID? UnRAID software? Hardware RAID?
To try to answer your question, you can certainly wipe and re-use the 6 TB drives, but if you pair it in a system with some larger drives, you will end up with two pools, one pool of 8 TB drives and one pool, or vdev, of “larger drive size”. Basically when grouping drives together for RAID, like your RAID10 system, ZFS prefers all the drives in a grouping to be the same size. That doesn’t mean all the drives in the enclosure have to be the same size, just all the drives you put together to span RAID 10 (or RAID 5 or RAID 6 or whatever) across.
I get wanting to reuse hardware, but I’d start from the top and set out your requirements, and then see if keeping the 6 TB drives, or perhaps selling them on eBay eg, is a better idea. 6 TB are relatively small, and are probably rather old with a lot of hours on them. OTOH, spreading data across more smaller drives can be more performant than having fewer larger drives.
You have 6 TB * 4 = 24 TB usable space currently in your RAID 10. How much space do you need now and how much do you expect it to grow? Is there any background to the choice of RAID 10? Do you have a workload (maybe your “AI setups”) that require fast HDD write performance?
If I was going to migrate this to an HL15 keeping the 6 TB drives what I would probably do is;
- put 7x new 6 TB drives in the HL15 as a single RAID Z2 (equivalent of RAID 6). VDEV, That would have 5 * 6 TB = 30 TB usable space and would survive any 2 drives failing.
- copy the data over the network or via other means from the old system to the new system. Because you have a set of mirrors, you may be able to install the specific four drives from one of the mirrors into the HL15 and mount those to do the copy. That would depend on details TBD.
- confirm you have 100% of everything you intended to copy
- re-confirm you have 100% of everything you intended to copy
- wipe the old drives and add them to the HL15. This fills all 15 bays of the HL15 with 6 TB drives.
- Create a second VDEV from 7 of the old drives. This would also be RAID Z2 like the first VDEV with 30 TB usable.
- Add this second VDEV to the pool with the first VDEV. This now gives you a RAID Z2 pool with 60 TB in which any two drives from either 7-drive VDEV group can fail before you would lose the pool.
If you got new larger drives the process would be similar, except in step 7 I would just keep two separate pools, not try to merge them. You can have a pool in ZFS where the VDEVs have different numbers of drives and drive sizes, but it is discouraged because of the way data gets striped across the drives.
Not sure if that helps.
For ZFS, you don’t need to populate all 15 drives, but you do need to expand the pool in groups of drives at a time they call vdevs. So what many people will do is start with 7 drives, then add another 7 drives together when they need to expand. :Leaving one bay for a hot or cold spare. Another option is to start with one 5-drive vdev, then add a second, then a third as needed. There is a recent ZFS addition that does let you add a disk at a time to a VDEV, but it comes with some performance quirks. It’s useful, but it’s by no means “I’m going to start with two drives then add one drive at a time as I need to until I fill all 15 bays”. And as with the other RAID stuff, the disk you add has to be the same size as the others in the VDEV.