If I understand correctly, the data on this drive is not needed (since you're trying to format it). If you provide full, clear and unambiguous answers to these questions, it will help members to better understand your situation and therefore to make useful suggestions.
aaron_uk wrote:
It is currently formatted to FAT32.
Are you having any problems at all reading or writing to the drive? Can you definitely add new files to the drive and read those same files?
Just to be clear, how many partitions are on this drive?
What version of Windows have you been trying to use, to format the drive?
I assume you're trying to format the drive as NTFS, as Windows itself wouldn't let you format a 500GB drive to FAT32 (although third-party utils can do that). Please confirm.
aaron_uk wrote:
I cannot use windows to format this HDD at all.
What exactly happens when you try to do this? What error message is displayed on the screen? Were you trying a quick or a full format? What error message(s) is/are logged in the Windows System event log when you try to do this?
aaron_uk wrote:
I have also tried to format it in DOS mode with no sucess.
Same 4 questions as previous point.
aaron_uk wrote:
only way to format it is to use an image file.
How did you create that image file in the first place? Is the image file that of a full disk (including MBR) or of a partition-only (excluding MBR)?
aaron_uk wrote:
I have also taken the HDD out of the casing and put it into a laptop hoping i can format it by installing windows onto it. this didnt work either.
That eliminates the original USB enclosure as the source of the problem. If you remember, can you tell us whether the error message(s) were the same for this test, as when the drive was in that enclosure?
aaron_uk wrote:
The HDD does work on FAT32 so its the the actual HDD
I'm not sure that I understand exactly what you mean by that comment - is there some link between FAT32 and the problem, based on your troubleshooting so far? Are there any other test results which you have got, but not mentioned so far, from any other troubleshooting that you've done?
Do you have the option to take that HDD to another PC and perform the same attempt to format it using Windows?
How did you first discover this problem? Can you remember anything unusual which happened between the last time you could successfully format the drive, and the first time that you couldn't?
Have you tried wiping / erasing (sometimes called "zero filling") the drive, and then formatting it?
Have you run the appropriate manufacturer diagnostic tool (e.g. WD DLG, Seagate SeaTools etc.) "long test" on the drive? If so, what was the result?
Have you collected the full SMART data (including raw attribute values) from the drive? If so, please attach the text file, or screenshot / photo of whatever GUI you used, containing the SMART data to your reply. Ideally, I would install smartmontools onto the PC, to be able to run "smartctl -x" and collect the drive's internal error log immediately after you've tried (and failed) to format the drive, but I don't know if that's something you can do.
Do you have any experience using Linux?