This isn't portable though, it's a GNU-specific "smart" things. Elsewhere, this overwrites the target device file.
cat foo.img > /dev/sda
works and should be portable. No control over the buffer size, though.Whatever behaviour you’re describing is not how POSIX mandates cp to work. In fact you can do this with busybox too.
cp will open("/dev/sda", O_WRONLY | O_TRUNC) and simply start writing to that file descriptor.