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Its a BUG in vista! If you don't safely remove device it locks it! I am not
the only one that had that issue .I don't care for Winblows.I wanna format all the partitions from linux and thats it.I already started my CEntOS image deploy anyways,bye bye MS crap!
Doesn't it help if you just use dd to write zeros over the disk, and then create a new filesystem there? Do you encounter errors?
EDIT: because I don't get how the usb key could be "locked" so that one can't write there at all, except for a manual switch that prevents writing. A filesystem can be encrypted, but it's pretty difficult to make it unwritable without destroying the device for good. I've seen that happening too, an "unsafe removal" of a usb key from a Windows machine may easily wreck the device so it's unusable (last time I did that, my 512MB key got rendered to seemingly 8MB of crap that couldn't be dealt with by any means - nice?).
Yeah it's ok; the usual bs is 512, but if you think 1M is ok for you, go for it. You could also just try using fdisk or something to remove the partitions & create new ones; could be easier.
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