The sixth-ranked American came through 1-6, 6-4, 6-2 and will take on world number two and Australian Open champion Aryna Sabalenka in Saturday's championship match.
Osaka has been unable to build momentum in her comeback, and her first round win over Jelena Ostapenko was her first in four years over a top-10 player.
Coco Gauff vs Aryna Sabalenka Highlights: Coco Gauff claimed her first Grand Slam title.
American teenager Coco Gauff defeated Czech Republic's Karolina Muchova to qualify for her maiden US Open Women's Singles final.
Coco Gauff captured the biggest title of her career on Sunday, powering past Karolina Muchova 6-3, 6-4 to win the WTA Cincinnati Open.
Iga Swiatek, unfazed by two lengthy rain delays, held off Karolina Muchova 6-1, 4-6, 6-4 to reach the quarter-finals of the WTA Montreal Open on Thursday
Iga Swiatek came through 6-2, 5-7, 6-4 to become the first woman since Justine Henin in 2007 to win back-to-back French Opens.
French Open 2023 Final, Swiatek vs Muchova Highlights: Iga Swiatek claimed the French Open 2023 title by defeating Karolina Muchova.
Iga Swiatek, 22, has yet to drop a set in this tournament but will be wary of her Czech opponent who knocked out second seed Aryna Sabalenka in the semi-finals
Karolina Muchova saved a match point and battled back from 2-5 down in the final set to shock world number two Aryna Sabalenka and reach her maiden Grand Slam final at the French Open on Thursday.