She will meet either teenage qualifier Linda Noskova or top-seeded Ons Jabeur in Sunday's final.
World number one Iga Swiatek downs Tunisia's Ons Jabeur 6-2 7-6(5) to claim her maiden trophy at Flushing Meadows and third Grand Slam title.
Fifth seed Ons Jabeur dominates semi-final against Caroline Garcia, winning 6-1, 6-3 in just 1hr 6min. In another semi-final, No. 1-ranked Iga Swiatek beats No. 6 Aryna Sabalenka 3-6, 6-1, 6-4.
In a year when Russian players were banned from Wimbledon, Moscow-born Elena Rybakina rallied from a set down to defeat Tunisia's Ons Jabeur 3-6 6-2 6-2.
Tunisia's Ons Jabeur lifted the spirits of an entire continent when she became the first Arab and first African woman to reach the Wimbledon final with a rousing 6-2 3-6 6-1 victory over her barbecue buddy Tatjana Maria.
Nadal, a 22-time Grand Slam champion, will play Nick Kyrgios for a place in Sunday's final.
Less than 24 hours after Serena Williams and Adrian Mannarino pulled out of matches after slipping and getting injured, more players have come forward to complain about the unsafe surface.
Ons Jabeur described herself as a "100% Tunisian product" having turned down opportunities to train abroad to continue developing her game at home.
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