OK I have cracked the problem and created a bootable Rescue Disk USB via alternative route.
Normal route via Avast UI to create a Rescue Disk fails for me as stated in posts above. Seems to be related to Avast automatically formatting the USB as NTFS when you select to overwrite and create a USB Rescue Disk. A NTFS formatted USB will not boot in UEFI mode on my Win10 machine.
My work-round method:
1. Format the USB as FAT32.
2. Downloaded rescuedisk.iso as if creating a Rescue Disk CD
3. Use Unetbootin (I already had downloaded) to create bootable USB with rescuedisk.iso
My BIOS then can see the USB and boots it correctly to Rescue Disk when USB chosen as boot device.
Bootable FAT formatted USB used to work straight out of the tin from the Avast UI, sadly no longer in my case, but that work-round does work for me.
What a pain that has been to sort out!