In the Sealed Archive dungeon you need to defeat a specific monster in order to unlock a gate to progress past the first tile set. The monster in question is called the Decayed Keymaster, he only spawns on a specific tile and currently that tile does not always spawn. I had an instance of completely clearing the initial area of the dungeon and the tile did not spawn thus I was unable to progress. This occurred twice and on the third dungeon instance the tile successfully loaded. This seems to be a similar situation to upgrading the little robot.
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I had this same exact issue where the mob needed wouldn’t spawn and full cleared the beginning twice and on the third try it spawned.
Just wanted to chime in and say that I just experienced this as well.
Going back to town and resetting the dungeon allowed me to roll a map where the NPC did spawn.
Same problem exists on the console. Zutara has probably nailed it - it’s an instancing issue like the robot thing.
Also occurred in my game.
Same boat, I’ve reset this thing like 4 times and can’t get him to spawn. Very annoying.
Exact same issue. Very frustrating. Reset 5 times with no luck.
I just had the same bug, he did not spawn, Reset the dungeon multiple times and no joy
Same issue! Need the aspect lol
Me too twice so far .
For some. reason you have to do it 3 times
Just had the same bug today, I only tried once. The keymaster never spawn
I’ve had it to where either he doesn’t spawn or he spawns behind the locked door, so I can’t reach him. There was one time where the door glitched & I was able to engage/kill him to get the key & open the door after the fact.
This happened to me too. Cleared the whole place. Went back over every portion and nada.
Near a year later this is still an issue
Yup, just happened to me.
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Same thing happened to me. How is this bug still there after nearly 1 year of first report?
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Still an issue. Happened just now in nightmare 0.
ugh! Welppppp! Exact same situation on my PS4 pro. I just spent 30 minutes of my life running around every corner of the Sealed archives like " WTF Blizzard!" Thanks for the clarification I will reset and try again. 
Same thing is still happening in S7. I haven’t tried to reset the dungeon, but the named monster to kill for the key has not spawned. I cannot proceed. Good to see that over a years worth of bug reports and it’s still not resolved.