Like Djokovic, she's never won the title, losing both of her chances, including the title match previous year to Garbine Muguruza.
In women's third-round action, reigning US Open champion Sloane Stephens was eliminated while Madison Keys, runner-up at Flushing Meadows a year ago, moved ahead.
It was a busy day for 10th seeded Djokovic, who came from behind to oust defending champion Grigor Dimitrov of Bulgaria 2-6 6-3 6-4 in the conclusion of a third round match carried over from Thursday. They're back for the 18th shared title match of their careers. "Hopefully I can get it done this time", he said.
The Belgian withdrew after one set of their semi-final clash due to injury after Federer had claimed the first 7-6 with the second tied at 1-1.
Wawrinka feels he is making strides ahead of the final major of the year at Flushing Meadows.More news: Sarri identifies exactly where Chelsea need to improve after win over Arsenal
The 20-time Grand Slam champion will face long-time rival Djokovic, who won Wimbledon last month having overcome his lengthy injury struggles to rediscover his best tennis. After losing his serve, Djokovic bashed his racket on the court three times, sending pieces of the frame flying. The racket-busting became a turning point., as he went on to do the business.
When he closed out the victory Saturday, he walked calmly to the net to congratulate Cilic and then raised both arms in triumph.
Halep, 26, beat the Belarusian 6-3 6-4 to reach her second final in as many weeks.
It was the second fightback of the day for Halep, who came from a break down in each set to overhaul Australian 16th seed Ashleigh Barty 7-5, 6-4 several hours earlier in the third round.
Halep has faced the most challenges from the rain, with one match suspended overnight Wednesday in the third set and then her third-round match held over for a day as well. She won her third title of the season last Sunday in Montreal. "I was really trying, but nothing".More news: Who is Omarosa? And why is she causing such a stir?
Known as more of a clay-court player, Bertens has reached a hard-court final for the first time, spending more time getting accustomed to the different style of play.
Asked about the rivalry, Djokovic played a straight bat: "I understand you want to ask me that question but out of respect to Goffin I don't want to answer it", he said in an on-court interview. I think I'm playing great in general.
A week of rain delays and double-duty days wore on players, many of whom wound up playing twice in a day. The World No.1's longest winning streak to date is 14, set in February and March 2015 as she won titles in Dubai and Indian Wells, followed up by a semifinal in Miami.
"My legs were pretty heavy", Kvitova said.More news: Amazingly preserved remains of 99 MILLION-year-old beetle found in amber
"I could see that he was unhappy, but I thought he was going to play on". "I just need to get out there and really fight, I was telling myself to fight", the two-time Wimbledon champion said. "I was really trying, but nothing".