If you are getting this error “Windows Was Unable to Complete the Format” that’s mean definitely something happen to your USB flash drive, doing formatting is the only way when you tried all methods to fix the corrupt USB pen drive. This will delete all data from your usb but might be save your USB pen drive, now let see how to format pen drive which is not formatting in the normal way, follow these steps to repair your pen drive.
1. Open Run type “diskpart” and hit “enter”
2. Now type these command one by one and hit enter after each command
list disk
Select disk 1
clean
create partition primary
active
select partition 1
format fs=fat32
3. Let it to complete 100% format, after 100% close this window, remove and reattach your pen drive; hope this will fix your usb issue