To me this indicates that some permanent damage has been done, either to the disk surface, the drive mechanism, or to the electronics of the drive controller.
I just formatted it again format to NTFS (Will not format to fat FAT32, unless an NTFS partion is present; even with 3rd party software such as swissknife v3, USBAdvance etc)
Now, it will not stay formatted at all, either in FAT32 or NTFS. I can format it as NTFS, but as soon as I add files to the drive, remove the device, then insert it again, all data is removed from it. It also becomes unformatted and 'Not Initialized.'
If the drive can not be formatted properly, even to NTFS format and when connected directly to a SATA bus of your computer, then something is obviously wrong with the drive at a hardware level. This goes beyond any 'soft' format errors, and I'm afraid I see no way to recover that drive.
I have taken the SATA drive out of the USB enclosure and placed it in my laptop, to rule out any USB interface problems, but it still does not work. I have ran the samsung diagnostics tool (since it is a samsung HDD inside)
That is just the normal Windows refusal to let you choose FAT32 for a large drive. That is why we use other programs to do such formatting. Once the drive has been formatted Windows has no problem using its FAT32 format for all file operations.
This was the very first method I tried, but I got an error saying the drive was too large to be in fat32, or that it had not been possible to format it.