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You don't just need to save Barcus in Grymforge for him to show up in Act 2, you also need to talk to him and convince him to join up with you, and possibly also talk to him while he's in your camp.
Grymforge[edit source]
It appears (just based on some simple testing in my current playthrough) that if you do the grymforge section first, when you go to the blighted village/windmill, Barcus is already dead.