Replace diskpart with PowerShell for more reliable Windows USB formatting

- Use PowerShell Format-Volume cmdlet as primary formatting method
- More reliable than diskpart with better error handling
- Get drive information before formatting for verification
- Keep diskpart as fallback method only
- PowerShell doesn't require script files and works more consistently
- Should resolve blank diskpart window and script access issues
- Modern approach using native Windows PowerShell cmdlets

usb_creator_gui.py

@@ -221,7 +221,7 @@ class WorkerThread(QThread):
         os.unlink(temp_iso)
 
     def write_usb_windows(self, source_dir):
-        # Windows USB writing implementation
+        # Windows USB writing implementation using PowerShell (more reliable than diskpart)
         import tempfile
         import subprocess
         
@@ -232,41 +232,106 @@ class WorkerThread(QThread):
             
         self.status.emit(f"Preparing USB drive {usb_drive}...")
         
-        # First, try to find the disk number for the USB drive
-        disk_number = None
+        # Use PowerShell to format the USB drive (more reliable than diskpart)
         try:
-            # Get disk number for the USB drive
+            # First, get drive information
+            self.status.emit("Getting drive information...")
+            drive_info_cmd = f'Get-Volume -DriveLetter {usb_drive[0]} | Select-Object DriveLetter,FileSystemLabel,Size'
             result = subprocess.run([
-                'wmic', 'logicaldisk', 'where', f'deviceid="{usb_drive}"',
-                'assoc', '/assocclass:Win32_LogicalDiskToPartition'
-            ], capture_output=True, text=True)
-            
-            for line in result.stdout.split('\n'):
-                if 'Disk #' in line:
-                    # Extract disk number
-                    import re
-                    match = re.search(r'Disk #(\d+)', line)
-                    if match:
-                        disk_number = match.group(1)
-                        break
-        except:
-            pass
-        
-        # If we couldn't find disk number, try alternative method
-        if disk_number is None:
-            try:
-                result = subprocess.run([
-                    'wmic', 'partition', 'where', f'bootable=true',
-                    'get', 'diskindex,deviceid', '/format:csv'
-                ], capture_output=True, text=True)
+                'powershell', '-Command', drive_info_cmd
+            ], capture_output=True, text=True, timeout=30)
+            
+            if result.returncode == 0:
+                self.status.emit(f"Drive info: {result.stdout.strip()}")
+            
+            # Format the USB drive using PowerShell
+            self.status.emit("Formatting USB drive with PowerShell...")
+            format_cmd = f'Format-Volume -DriveLetter {usb_drive[0]} -FileSystem FAT32 -NewFileSystemLabel "MBetter Live" -Force -Confirm:$false'
+            
+            result = subprocess.run([
+                'powershell', '-Command', format_cmd
+            ], capture_output=True, text=True, timeout=120)
+            
+            self.status.emit(f"PowerShell format exit code: {result.returncode}")
+            if result.stdout:
+                self.status.emit(f"PowerShell stdout: {result.stdout}")
+            if result.stderr:
+                self.status.emit(f"PowerShell stderr: {result.stderr}")
+            
+            if result.returncode != 0:
+                raise Exception(f"PowerShell format failed (exit code {result.returncode}): {result.stderr}")
                 
-                # This is a fallback - we'll try disk 1 if we can't determine
-                disk_number = "1"  # Most common for first USB drive
-            except:
-                disk_number = "1"
+        except subprocess.TimeoutExpired:
+            raise Exception("USB formatting timed out. Please try with a different USB drive.")
+        except subprocess.CalledProcessError as e:
+            raise Exception(f"Failed to format USB drive with PowerShell: {e}")
+        except Exception as e:
+            # Fallback to old diskpart method if PowerShell fails
+            self.status.emit("PowerShell formatting failed, trying diskpart as fallback...")
+            return self._write_usb_windows_diskpart_fallback(source_dir)
+        
+        # Copy all files from source directory to USB drive after successful formatting
+        self.status.emit("Copying files to USB drive...")
+        self._copy_directory_windows(source_dir, f"{usb_drive}\\")
+        
+        # Make it bootable by ensuring boot files are in the right place
+        self._make_bootable_windows(source_dir, usb_drive)
+        
+        self.status.emit("USB creation completed successfully!")
+
+    def _write_usb_windows_diskpart_fallback(self, source_dir):
+        """Fallback diskpart method for when PowerShell fails"""
+        # Get USB drive letter
+        usb_drive = self.usb_device
+        if not usb_drive.endswith(':'):
+            usb_drive += ':'
+        
+        # Find disk number for the USB drive
+        disk_number = "1"  # Default fallback
         
-        # Create diskpart script to format the USB drive
+        # Create diskpart script
         diskpart_script = f"""select disk {disk_number}
+        
+        # Write diskpart script to accessible location
+        script_filename = f'diskpart_script_{os.getpid()}.txt'
+        script_path = os.path.join(os.path.expanduser('~'), script_filename)
+        
+        try:
+            with open(script_path, 'w', encoding='cp1252') as script_file:
+                script_file.write(diskpart_script)
+            
+            self.status.emit(f"Diskpart fallback: Created script at {script_path}")
+            
+            # Run diskpart
+            result = subprocess.run([
+                'diskpart', '/s', script_path
+            ], capture_output=True, text=True, timeout=60)
+            
+            # Clean up script
+            try:
+                os.unlink(script_path)
+            except:
+                pass
+            
+            if result.returncode != 0:
+                raise Exception(f"Diskpart fallback failed (exit code {result.returncode}): {result.stderr}")
+                
+            # Copy files after successful formatting
+            self.status.emit("Copying files to USB drive...")
+            self._copy_directory_windows(source_dir, f"{usb_drive}\\")
+            
+            # Make it bootable
+            self._make_bootable_windows(source_dir, usb_drive)
+            
+            self.status.emit("USB creation completed successfully with diskpart fallback!")
+            
+        except Exception as e:
+            if os.path.exists(script_path):
+                try:
+                    os.unlink(script_path)
+                except:
+                    pass
+            raise Exception(f"Diskpart fallback failed: {e}")
 clean
 create partition primary
 active