As far as I know, it seems that as long as the player character has to leave the dock due to the plot, Karlach will be burned to death. Even if Wyll has become the Blade of Avernus.
The following situations will cause Karlach to be burned to death:
1.When the player plays the origin Astarion, if he chooses not to ascend, Astarion cannot persuade Karlach to survive and return to hell because of his fear of the sun.
2.The player plays the role of Origin Lae'Zel , and chooses to ride the dragon and leave at the end.
3.If you romanced Lae’Zel and sided with Orpheus, flying into the sunset with her.
4.The player chooses to commit suicide at the end.
I don't understand why we worked so hard to complete all the tasks for Wyll and Karlach, but Karlach died needlessly because we had to leave the dock at the end, and Wyll didn't even have any suggestions about it ?
I think Larian has to fix this.