No, actually Ash was never blacklisted. Chalte Chalte she was dropped after the on set fiasco therein right after Veer Zaara didn’t materialise.
Sanjay Leela bhansali’s Bajirao Mastani didn’t work out coz Salman and Ash had broken up by then. Besides, these 3 films no one banned or stopped working with Ash. She was always in demand. She became very famous in west and was sought after there.
Actually, Kjo told on the Komal Nahta show that each and every movie that he directed he approached Ash to star in it. But something or the other didn’t work out.In fact, K3G Ash was almost signed coz Kjo wasn’t sure Kajol would do it after marriage but then Kajol called up Karan telling she will do it so he had to let Ash go.
Not true. The reason she went to Hollywood is because she was basically a pariah in Bollywood. She was still making movies, but not the big-budget A-List movies she was supposed to be making (Dil Ka Rishta is a wonderful film but no Devdas or Taal). Her breakup with Salman and the aftermath with Vivek Oberoi made them both persona non grata. She was never going to work with Salman again. SRK had cut her out of Chalte Chalte, Veer-Zaara, and other films. He also made sure other BW bigwigs weren't working with her. Aamir Khan blacklisted her because he wanted her for Mangal Pandey but she refused. He was insulted and said he would never work with her again. What saved Aish was marrying into Big B's family which gave her prestige again and protection from Salman.
Bhansali's films were constantly getting delayed and delayed, with or without casting issues. He even wanted Salman and Aish for Padmavati. Aish said she would do it but only if she had no screentime with Salman. Salman said he wouldn't do the movie if there were no scenes with Aish.
K3G was before the Chalte Chalte incident. If I'm correct, Karan asked her to play the Tina role in KKHH as well but Aish refused so he's been wanting to work with her for a while. However, I've never heard of her being attached to KANK or Kal Ho Naa Ho. The former was meant for Kajol but then went to Rani when Kajol said no. Kal Ho Naa Ho was meant for Kareena but she demanded pay equal to SRK so Karan rejected her and cast Preity instead. Rani said she was upset because she thought Karan would have cast her. I haven't heard of Karan trying to cast Aish in anything after the Chalte Chalte incident that involved SRK until she got married.
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