A resounding 6-4 6-1 win over Kasatkina saw Andreescu advance to the last four of a WTA Tour grass-court tournament for the first time.
The last time she reached the semi-finals in any event was the 2021 Miami Open, where she finished as runner-up after retiring with an ankle injury in the second set of the final against Ash Barty.
Andreescu limited Kasatkina to just 17.6 per cent of the points behind the Russian's second serve and saved four of the six break points she faced to book a meeting with Simona Halep.
Former world number one Halep sent down 10 aces and converted all three of the break points that came her way in a 6-2 6-1 success over Amanda Anisimova.
The other semi-final will be an all-French affair after Alize Cornet and Caroline Garcia downed home hopes Angelique Kerber and Sabine Lisicki respectively.
After going all the way in Nottingham and Birmingham this month, Haddad Maia progressed to the semi-finals of the Eastbourne International courtesy of a walkover against Lesia Tsurenko.
Next up for Haddad Maia is Petra Kvitova, who she beat in straight sets in the first round in Birmingham, after the Czech ended Harriet Dart's run to the quarter-finals with a 6-3 6-4 win.
Jelena Ostapenko cruised to a 6-3 6-2 victory against Anhelina Kalinina and will take on Camila Giorgi for a place in the final. Giorgi comfortably overcame lucky loser Viktoriya Tomova 6-2 6-1 in 64 minutes.
Seventh seed Kasatkina had no answers in Stuttgart as she fell to a 6-1 6-1 defeat against Badosa, who recorded the ninth top-10 victory of her career and first in exactly 12 months.
Badosa has won 29 clay-court matches in the last three seasons – only Ons Jabeur (35) and Iga Swiatek (30) have won more – but the Spaniard had to enter this tournament as a wildcard.
The 25-year-old was as high as second in the world last year but has fallen to 31st, and she outlined her goal to reach the top once more after her first-round win set up an all-Spanish meeting with Cristina Bucsa.
When asked about her ambitions to return to the world's top three, Badosa said: "That's what I'm working on every day. That's one of my goals – I want to be back on the top.
"I like to play big matches, I like to be in the last rounds of the tournaments. I still know I have that level. I still know I was that player. I still believe in myself, and I hope I'm back there very soon."
Jelena Ostapenko eased into the second round with similar dominance after downing Raducanu 6-2 6-1 in just 58 minutes, teeing up a meeting with world number four Ons Jabeur on Wednesday.
Latvian Ostapenko powered 19 forehand winners and went unbroken, acknowledging in her on-court interview that familiar aggression was key to her success in the battle of two one-time grand slam winners.
"I knew against her the main thing was to step in the court," said former French Open winner Ostapenko. "I missed some balls, but I tried to be aggressive all the time when it was possible.
"Just try to take the ball early, don't give her many chances. And finally, I'm back on clay, my favourite surface."
Barbora Krejcikova was another straight-sets winner, scoring a 6-2 6-0 triumph over Liudmila Samsonova, with the reward for the 2021 Roland Garros champion being a tricky clash against second seed and Australian Open winner Aryna Sabalenka.
There was no such ease for Anastasia Potapova in a battling 6-3 3-6 7-6 (7-4) victory over Petra Martic, the Russian's ninth third-set win in 2023 – no WTA Tour player has managed more.
Tatjana Maria overcame Ylena In-Albon 6-2 4-6 7-6 (7-4) in another enticing clash, while Beatriz Haddad Maia advanced after Martina Trevisan was forced to retire when trailing 7-5 1-1 due to a right thigh injury.
Bencic was due to go up against Veronika Kudermetova in the second scheduled semi-final on Friday, only for the Russian to withdraw due to a hip injury.
It was a similar story for Kasatkina, who received a walkover after Paula Badosa pulled out of their match, citing a thigh problem.
While Bencic and Kasatkina will now get the chance to claim a trophy early in the season, the focus for Badosa and Kudermetova will be on regaining fitness in time for the Australian Open, which starts next week.
Badosa was confident she can recover for the upcoming major, where she has been drawn against American Caty McNally in the first round.
"I'm really disappointed that I had to withdraw because I was really looking forward to the match," Badosa told reporters.
"When I was playing [against Beatriz Haddad Maia], it was a very tough match, especially physical, so I felt a little bit in my abductor. I felt like I pulled it a little bit.
"I feel a little bit worse, so I have the Australian Open ahead, and I hope I can recover for that."
Badosa needed two hours and 35 minutes to get past the Brazilian on Thursday, having knocked off Anett Kontaveit and Kaia Kanepi in the earlier rounds.
"I played three really good matches," the Spaniard said. "I think that helps me, as well, on my confidence for the tournaments ahead. Now it's something that I cannot control, so it is what it is."
At the Hobart International, Elisabetta Cocciaretto set up a showdown with Lauren Davis.
Sofia Kenin, the 2019 champion, fell 7-5 4-6 6-1 to world number 67 Cocciaretto, who has reached her first Tour-level singles final.
"It’s unbelievable for me to be here in the final of such a great tournament, and I’m really happy about my performance," Cocciaretto said.
"[Kenin is] a very good player, I was a junior when she won the grand slam [2020 Australian Open], so for me it's an honour to play against her."
Davis, meanwhile, saw off Anna Blinkova in straight sets. She has not featured in a Tour-level final since clinching the trophy in Auckland in 2016.
Both Bencic and Kasatkina did not have to play a semi-final after their respective opponents, Veronika Kudermetova and Paula Badosa, both pulled out with injuries.
Bencic romped to victory in the final though, dropping just two games against her Russian opponent to lift her first title in Australia.
The match lasted just 67 minutes, as the 2021 runner-up converted five of her seven break point opportunities while not facing a single break point herself.
Bencic rattled off eight games in a row to start the final, and though Kasatkina did save some face with a couple of holds late on, the world number 13 finished the job to win in straight sets ahead of the start of the Australian Open next week.
"I'm happy I could show my work here on the court," Bencic told reporters at a post-match news conference. "I thought I played some great matches from the start of the tournament and also against different kind of opponents so I really could test myself out there in every way and just go confidently into the Australian Open."
At the Hobart International, Lauren Davis ended a six-year title drought with a 7-6 (7-0) 6-2 triumph over Elisabetta Cocciaretto in an all-unseeded final.
In the opening set, every game went to serve until the tie-break, when Davis found three crucial breaks to take the advantage heading into the second stanza.
But the second set was not the same tight affair as Cocciaretto, playing in her first Tour-level singles final, collapsed to a 5-0 deficit to leave her staring down the barrel of defeat.
Davis, who herself was playing in a first Tour-level final since winning the trophy in Auckland in 2017, overcame losing the next two games to take the title having not lost a set at the tournament.
Davis was delighted after the match, saying: "I have a lot of emotions going through my body right now. I'm just really happy, really excited. I really had to play my best in order to win today."
Despite making a strong start, fourth seed Pliskova faltered and lost 1-6 6-4 6-4 to the world number 127 in the pair's last-32 match.
Boulter said: "I'm super-proud of myself today. I went out there and didn't feel great on court, and I worked so hard to battle and fight, and against a player like that it means so much to me, coming through that."
There was another major shock win for a British player later in the day as Jodie Burrage knocked out top seed Paula Badosa, the world number 169 triumphing 6-4 6-3 against a player who will be seeded fourth at Wimbledon.
Defending champion Jelena Ostapenko beat Ajla Tomljanovic 6-4 6-4 and two-time Wimbledon winner Petra Kvitova saw off Donna Vekic 6-1 7-6 (7-1), while Beatriz Haddad Maia's strong form on grass continued with a 6-4 3-6 6-3 victory over Estonian veteran Kaia Kanepi.
Brazilian left-hander Haddad Maia is coming off the back of title wins in Nottingham and Birmingham and stretched her winning run on grass to 11 matches.
There were also wins in Eastbourne for Camila Giorgi, Madison Keys and Barbora Krejcikova, but Greek third seed Maria Sakkari bowed out, losing 3-6 7-5 6-4 to Ukrainian Anhelina Kalinina.
At the Bad Homburg Open in Germany, the 2019 Wimbledon champion Simona Halep scrambled for a 4-6 6-3 6-4 win against Katerina Siniakova, and sixth seed Amanda Anisimova came from a set down to see off Alison van Uytvanck in a third-set tie-break.
Bianca Andreescu saw off Martina Trevisan 6-3 6-1 and Angelique Kerber also won in straight sets, while top seed and recent French Open semi-finalist Daria Kasatkina reached the quarter-finals with a 6-1 3-6 6-1 win over Germany's Jule Niemeier.
Kasatkina will be absent from Wimbledon due to the ban on Russian players.
Kasatkina, who is enjoying a career-high ranking, got the job done in straight sets despite struggling with her serve, committing all nine of the match's double faults.
While she was only able to win a below-par 58 per cent of her service points, she also won 58 per cent of her return points, and it was that ability to deal with the Spaniard's serve that proved to be the difference.
Kasatkina will play France's Diane Parry in the semi-final after she got the better of Germany's Tatjana Maria 6-4 6-7 (6-8) 7-6 (7-4) in a near three-hour tussle.
Parry only had one ace compared to Maria's 10, but she excelled in the longer rallies, with her return success rate jumping up from 16 per cent to 47 per cent when she was able to see a second serve.
Australia's Daria Saville will contest the other semi-final after her 6-3 6-0 domination of China's Xiyu Wang, and she will play Ukraine's Marta Kostyuk after she defeated Canada's Rebecca Marino 6-2 4-6 6-2.
Meanwhile, Liudmila Samsonova continued her terrific run at Tennis in the Land as she beat Magda Linette 6-4 6-3.
Samsonova is yet to lose a set at the tournament, but will face her toughest test next when she meets Bernarda Pera in the semi-final.
Pera, who previously eliminated top seed Barbora Krejcikova in straight sets, came out on top against American compatriot Sofia Kenin 6-2 5-7 6-3, despite creating one fewer break point opportunity.
Alize Cornet is also yet to lose a set on her run to the semi-final, proving too strong for Shuai Zhang 6-4 6-2.
Cornet will play Aliaksandra Sasnovich for a place in the final after the Belarusian pulled away in the second set of her 6-4 6-1 win against American Madison Brengle.
Russia's Kasatkina made her deepest grand slam run earlier this year by reaching the semi-final of the French Open, where she lost to world number one Iga Swiatek, and with this singles title – the fifth of her WTA career – she has claimed a career-best ranking of ninth in the world.
Against Rogers, the story was how the effectiveness of Kasatkina's serve continued to improve the further the match went on.
In the hard-fought opening set, Kasatkina won just 53 per cent (26-of-49) of her service points, allowing two breaks of serve and then flailing in the tie-break to drop five consecutive points.
Something changed from that point on, with Kasatkina improving to take 69 per cent (18-of-26) of her service points in the second frame, and that jumped again to 76 per cent (16-of-21) in the decider as she either figured something out, or Rogers ran out of steam.
Kasatkina did not allow a single break point opportunity after the first set, while converting four of her six chances to take a double-break in both the second and third.
Rogers had not lost a single set in her four matches to make it to the final, putting the exclamation point on a terrific run from Kasatkina that included wins over world number 27 Elena Rybakina, world number six Aryna Sabalenka and world number three Paula Badosa.
In the first game of the day, Canadian Fernandez edged a three-set thriller 6-3, 3-6, 6-3 against Madison Keys to be the first to book her place in Saturday's final.
Having taken the first set, Keys would fight back to take the game to a decider. Despite serving three aces, Fernandez would capitalise after earning an early break point to see out the triumph.
Later that afternoon, Kasatkina would reach her fourth final this year as she came through in another three-set encounter 6-3, 5-7, 3-6 against Jasmine Paolini.
The Italian secured an early break in the third game and would cruise to a first set win, only for Kasatkina to roar back in the second as the pair traded blows throughout.
But an error-strewn final set from Paolini was punished by the Russian, with the Italian threatening a comeback but was unable to recover as she sent a ball long to confirm Kasatkina's place in back-to-back finals at Eastbourne.
Data Debrief: Eastbourne set for intriguing final
Fernandez's victory over Keys was her first against the American, with their only previous meeting back in 2021 at Roland-Garros. The Canadian also ended the contest having won 70% of her first serve points.
Kasatkina won her third game against Paolini, having lost in consecutive games against the Italian. The world number 14 finished was made to work for the victory however, saving 10 of the 14 break points she faced.
Kasatkina lost her previous two major quarter-finals in 2018, but she broke new ground with a 6-4 7-6 (7-5) victory at Roland Garros on Wednesday.
The 20th seed will face Iga Swiatek or Jessica Pegula for a place in the final after ending Kudermetova's best run at a grand slam.
Kudermetova paid the price for 50 unforced errors in her maiden major quarter-final on Court Philippe-Chatrier, where Kasatkina overcame the nerves to move into the last four.
It was Kudermetova who drew first blood when she broke to lead 3-1, but she failed to consolidate as a tenacious Kasatkina responded immediately.
The two 25-year-olds both fended off a couple of break points in their next service games, but Kasatkina edged in front for the first time courtesy of a sublime cross-court winner to take a 5-4 lead after a terrible miss from Kudermetova with the court wide open.
A steely Kasatkina was moving superbly and served out the set, before moving into a 3-1 lead in the second set after three consecutive games went against the serve.
The 29th seed was struggling to find her rhythm, but she was level at 4-4 when her compatriot overcooked a forehand.
Kasatkina had looked edgy in that service game, yet she had an opportunity to serve for the match when a Kudermetova backhand struck the net cord and landed on her side of the net.
A nervy Kasatkina was unable to serve it out but held to force a tie-break after Kudermetova called for treatment on her left foot.
Kasatkina took a 6-1 lead in the breaker following a string of errors from Kudermetova and finally finished it off with her fifth match point, executing a drop shot to perfection.
Data Slam: No setbacks for Kasatkina in Paris
Kasatkina has not only put together her longest run in a grand slam, she has done so without dropping a set. While it was certainly not all plain sailing in the quarter-final, she showed her strength of character to come through another test in straight sets.
WINNERS/UNFORCED ERRORS
Kasatkina – 16/25
Kudermetova – 38/50
ACES/DOUBLE FAULTS
Kasatkina – 0/3
Kudermetova – 3/2
BREAK POINTS WON
Kasatkina – 5/17
Kudermetova – 4/7
The Russian delivered a convincing 6-2 6-2 victory over the Italian with a convincingly mature performance, to reach the last eight at Roland Garros for the second time in her career.
Kasatkina has yet to drop a set and has conceded just 14 games across her four matches at Roland Garros so far.
The 20th seed has previously spoken about wanting to showcase a more mature approach to her game, and mooted that she has increased her focus in her overall performances.
"Why are you asking me this?" Kasatkina quipped in her post-game briefing before laughing when asked in what ways she has matured – and where she has not.
"I want to say I've become much more mature and that's it. [I'm] not thinking how exactly.
"But as I said, with the decisions on the court, with my time management off the court as well I'm trying to be more focused on what I'm doing, what is important, not the kid bulls***, let's say.
"And that's it, because it's very tough to keep the focus and it's very easy to lose it. So I'm working a lot to be more focused on my job."
Kasatkina will face compatriot Veronika Kudermetova in the last eight after she fought back to beat American Madison Keys.
Kasatkina won an all-Russian showdown with Veronika Kudermetova on Court Philippe-Chatrier 6-4 7-6 (7-5) to break new ground at a major on Wednesday.
The 20th seed had lost her previous two grand slam quarter-finals in 2018, but she was not denied on this occasion in Paris.
Kasatkina will do battle with Swiatek for a place in the Roland Garros final on Thursday after the world number one beat Jessica Pegula in straight sets.
Top seed Swiatek has beaten Kasatkina twice in hard-court events this year and the Pole is on an astonishing 33-match winning run.
Yet Kasatkina has not dropped a set at the French Open and the 25-year-old is relishing the challenge of playing the biggest match of her career.
She said: "We played a few times this year. Okay, I lost those matches, but it was a different story. It was a hard court, beginning of the year, I was not in the same shape as I am now.
"I cannot compare what we are going to have tomorrow and what we had in February, March when we were playing. It's going to be completely different match. I want to win a lot, she wants to win as well, and it's going to be a good match.
"You never know what's going to happen in the semi-final of a grand slam, so it's going to be fun and that's it."
Kasatkina will savour her best performance at a major, but is hungry for more.
"I have no time to relax, I'm playing already tomorrow. So a little bit of time to enjoy it, because still it's special for me, a first semi-final," she added.
"But I know that tomorrow is another mountain in front of me which I have to climb and that's it. Maybe it's even better that I don't have much time to think about how good it is to be in the semi-finals, so I have another battle."
As she prepares to face the all-conquering tournament favourite, Kasatkina does not believe she has ever been in better shape.
She said: "Mentally and physically I feel the best I ever was, which is good, because it means that I'm improving. But I don't feel safe, because when you're in the comfort zone it means there's something wrong.
"I think it's better to feel something behind you, so you don't relax much. I think I'm always ready, you have to be always be ready.
"It doesn't have to be like, 'Oh, I'm so bad, and what do I have to do now?' But if you are ready and you know how to get out of this, this is also what I learn."
The surprise 2020 Roland Garros champion is this year's hot favourite for the title, and she extended her astonishing winning run to 34 matches with a 6-2 6-1 victory on Friday.
It was magnificent from top seed Swiatek, who from 2-2 in the first set won 10 of the next 11 games, sealing victory with an ace.
Kasatkina is a former French Open girls' champion and this was her first grand slam semi-final at the age of 25, with the Russian having largely breezed through to this round.
A former world number 10, now ranked at 20 by the WTA, Barcelona-based Kasatkina would have returned to the top 10 had she reached the final in Paris. However, she had lost three times to Swiatek already in 2022, winning only 11 games in those matches, and so this landslide result was perhaps inevitable.
Kasatkina's start was bright enough, recovering an early break, but Swiatek soon began to take control, moving well and finding her range, crucially keeping her winners count higher than the unforced errors.
Picking off Kasatkina's soft second serve was helping Swiatek's cause, and a stunning forehand clean winner from one such scenario sealed a 5-1 lead as Swiatek closed in on the title match.
She wrapped it up in just an hour and four minutes, the potential of the match-up never materialising as Swiatek, who spent time listening to Led Zeppelin before coming on court, left Kasatkina dazed and confused.
Data slam: Swiatek exploits Kasatkina weakness
Swiatek, who was ranked at number 54 when she took the title as a teenager, was still a work in progress at the time. She is fast becoming the finished article and Kasatkina found the 21-year-old's power and precision overwhelming. Here, Kasatkina dropped sets for the first time in the tournament, and her second serve was made to look ridiculously meek. Kasatkina won only three of 14 points on her second serve, and that is a recipe for defeat.
WINNERS/UNFORCED ERRORS
Swiatek – 22/13
Kasatkina – 10/24
ACES/DOUBLE FAULTS
Swiatek – 1/2
Kasatkina – 2/2
BREAK POINTS WON
Swiatek – 5/10
Kasatkina – 1/1
Swiatek, who is reading the Alexander Dumas novel The Three Musketeers while in Paris, is hoovering up classic culture at a young age.
The 21-year-old has made no secret of her love for hard rock and rates AC/DC among her favourite bands.
Rather than search for focus by listening to chillout music or meditation tapes, Swiatek plays by her own rules and served up a 6-2 6-1 thumping of Kasatkina after indulging in a little Page and Plant.
"I try to treat every match the same way, because if I realise this is one of the biggest matches of the season it can stress me out. So I'm trying to focus on the tasks and I listen to music when I work out," Swiatek said in an on-court interview.
Asked which artist she was listening to, Swiatek said: "Led Zeppelin. It's really helping me out so I can start with being proactive. I use everything to help me."
Swiatek won the 2020 French Open final as an outsider ranked 54th in the world, but she is a hot favourite to be champion this year after climbing to number one.
Friday's win was a 34th in succession for the Polish player, who has won five tournaments in that run.
She said: "It's a pretty special moment, and I'm really emotional. I'm so grateful to be in that place and be healthy and be able to play my game. It's amazing and I love playing here."
She is feeling plenty of love from the Roland Garros crowds, particularly a strong contingent from Poland.
"It's easier to play matches with that kind of support, and I've had that in every place I've played this year and it's still surprising for me," she said.
"When I started playing the WTA, basically right after my first year it was COVID and I wasn't able to see how many Polish people would come, and it's still overwhelming and it surprises me how much they're supporting."
As well as being open about her musical heroes, Swiatek is unabashed in making clear her affection for Rafael Nadal, the 13-time French Open winner who is through to another semi-final this fortnight after beating Novak Djokovic on Tuesday.
"He's inspiring me in every aspect, on court and off court, because he's so humble and down to earth," Swiatek said.
"He's the kind of guy who's always saying hi, and it's amazing because it seems the success didn't change him and he's still the same, a great person.
"When I watched this year's Australian Open final [against Daniil Medvedev] it was just amazing. Even I had doubts and I could see how he was trying to find solutions and trying to get better during the match, and he did and he won, so he's a huge inspiration. Not only here but on every court, it's just great to watch him play."
The world number one was in sensational form heading to Roland Garros after winning five consecutive tournaments.
And there has appeared little prospect of Swiatek slowing in Paris, with her 6-2 6-1 defeat of Daria Kasatkina securing a sixth WTA Tour final appearance in a row.
Swiatek is the first player to make six finals in the first six months of the year since Serena Williams reached seven before the halfway mark in 2013.
She has also now matched Williams' best winning run this century, with only Novak Djokovic in 2011 (43), Roger Federer in 2006 (42) and Venus Williams in 2000 (35) enjoying longer sequences across both the ATP and WTA Tours since 2000.
Swiatek's feats are all the more impressive given her age, as she turned 21 just this week.
Now with 20 wins at Roland Garros, the 2020 champion is the youngest female player to that mark since Martina Hingis in 1999.
Only eight women – Evonne Goolagong, Chris Evert, Steffi Graf, Monica Seles, Arantxa Sanchez Vicario, Hingis, Kim Clijsters and Ana Ivanovic – have reached their second French Open final at a younger age.
The winner of the Tracy Austin Group match in Fort Worth knew they would face Maria Sakkari in the last four and it was world number six Garcia who got the job done.
Frenchwoman Garcia won 4-6 6-1 7-6 (7-5) in a topsy-turvy contest that was finally settled in two hours and 27 minutes.
Kasatkina won four games in a row to take the opening set, but sixth seed Garcia stormed back to level the match in emphatic fashion as her aggressive approach paid off.
Russian Kasatkina twice came from a break down in a tense decider and fended off six break points in the ninth game of the final set to hold for a 5-4 lead, but Garcia held her nerve in the tie-break to advance.
Garcia and Sakkari will do battle for a place in the final on Sunday, with the winner facing either Iga Swiatek or Aryna Sabalenka.
WINNERS/UNFORCED ERRORS
Garcia- 42/48
Kasatkina - 16/26
ACES/DOUBLE FAULTS
Garcia - 4/2
Kasatkina - 1/8
BREAK POINTS WON
Garcia - 6/14
Kasatkina - 5/7
Halep's last grass-court match was the impressive 6-2 6-2 defeat of Serena Williams in the 2019 Wimbledon final.
While Monday's triumph may not have been of comparable importance, the 6-1 6-4 win was a positive step in Halep's preparation for a return to SW19 later this month.
After saving three break points in the very first game, the former world number one rarely looked in trouble against her Ukrainian opponent, breaking Tsurenko's serve at the first opportunity.
She repeated the feat to go 5-1 up before serving to love to close out the set, though Tsurenko showed a bit more fight at the start of the second – only one of the first five service games was a hold.
Halep ultimately weathered the storm, however, taking her chance to go 5-4 up and once again served to love to wrap up the match.
Seeded second, Halep was the only seed in action on Monday and will meet home favourite Harriet Dart next, with the Brit impressively seeing off Camila Osorio – ranked 45 places better off – 6-2 6-0.
In Berlin, fourth and sixth seeds Karolina Pliskova and Daria Kasatkina secured their passage to the last 16.
Pliskova struggled initially against Kaia Kanepi but went on to produce two near-flawless sets to progress 6-7 (6-8) 6-0 6-0 – Kasatkina also came from behind, with an ankle injury to Anhelina Kalinina potentially aiding her 5-7 6-3 6-1 victory.
Bianca Andreescu was also among the winners in Berlin, with the Canadian beating Katerina Siniakova to claim only her second career success on grass.
Unseeded 29-year-old American Rogers has knocked off top seed Maria Sakkari along with Amanda Anisimova and 2019 US Open winner Bianca Andreescu on her way to the decider.
Rogers is also yet to drop a set, maintaining that run against the higher-ranked Kudermetova for a 6-3 6-4 victory in one hour and 20 minutes.
The triumph marks Rogers' biggest final in her career and her first on tour in six years.
Rogers, who trailed 2-0 in the second set, broke Kudermetova's serve with her second match point to clinch victory.
Second seed Badosa was bundled out by Kasatkina 6-2 6-4 in 46 minutes in the other semi-final on Saturday.
Badosa did not appear 100 per cent physically throughout the match and Kasatkina capitalised to secure back-to-back finals in San Jose.
The Spaniard had three break points in the decisive game before Kasatkina converted her first match point.
Kaia Kanepi and Liudmila Samsonova both powered their way into the Citi Open final with comfortable victories on Saturday.
Sixth seed Kanepi ruthlessly swept aside Australian Daria Saville 6-3 6-1 in one hour and 13 minutes, moving her closer to her fifth career title. The 37-year-old Estonian blasted 18 winners for the match.
World number 60 Samsonova proved too good for China's Wang Xiyu, winning 6-1 6-1 in one hour and seven minutes. Samsonova's big hitting was a key feature behind her win with four aces and 17 winners.
Jabeur trailed a break in both sets but won in 109 minutes, aided by a three-hour rain delay at 5-3 down in the first frame allowing her to re-group.
The Tunisian had been a double break down at 4-1 in the first set, with Jabeur breaking Kasatkina when she served for the set at 5-2.
Jabeur's progress means she has reached her 11th WTA level final, this marking her first since the 2022 US Open which she lost to Iga Swiatek.
Jabeur lost last year's Charleston final to Belinda Bencic and the two may face off again in this year's decider, with the Swiss fourth seed leading top seed Jessica Pegula 7-5 6-6 (2-4) before rain forced their semi-final to be postponed until Sunday.
Bencic looked to have blown a 5-2 first-set lead, failing to serve out the opening frame before Pegula squared it up. But Bencic held serve, then broke Pegula to love to claim the lead.
There were breaks in the opening two games of the second set before it went to serve, until rain intervened with Pegula having a slight advantage in the tiebreaker.
Play will resume on Sunday not before 1:30pm local time, with the final scheduled for Sunday evening.
Second seed Tatjana Maria advanced to her second straight Copa Colsanitas final in Bogota, winning 6-3 6-4 over Briton Francesca Jones.
Maria will face either Peyton Stearns or Kamilla Rakhimova in Sunday's final.
The world number 14, who finished as runner-up to Madison Keys last year, had conquered Emma Raducanu and Jasmine Paolini en route to her fourth final of 2024.
She broke the 2021 US Open runner-up in the very first game and wrapped up the opener with another break in the ninth game, having held off some fierce pressure on her own serve.
Another swift break in the second set had seemingly set up more of the same, but Fernandez fought back from 3-0 down to go 4-3 up. However, the Canadian failed to hold serve again from then on as Kasatkina assumed control, wrapping up her victory in just under two hours.
Elsewhere on Saturday, 20-year-old Diana Shnaider won her second title of 2024 at the Bad Homburg Open, edging out Donna Vekic 6-3 2-6 6-3 in the final.
The Russian's efficiency told in a back-and-forth contest as she converted four of her six break points, becoming the youngest player on the WTA Tour to capture multiple titles this season.
Data Debrief: Kasatkina heads to SW19 in form
Kasatkina is now 6-1 on grass this year and possesses a fine 33-17 record on the surface throughout her career.
Having made the quarter-finals at Wimbledon in 2018, she will be targeting another deep run this year, seeded 14th and drawn to face Zhang Shuai in the first round.
Kasatkina trailed 4-1 in the first set but rallied to win the opening frame in a tiebreak, before dominating the second set to win 7-6 (8-6) 6-3 in one hour and 40 minutes.
The victory is Kasatkina's 41st of the year and 25th on the hard-court surface this season. Kasatkina is 29-0 this season when she wins the first set.
Gauff has now suffered two singles losses and two doubles defeats in Fort Worth this week, producing an erratic performance, where she committed 34 unforced errors compared to the Russian's 10.
Kasatkina had to earn the victory, with the first set lasting 66 minutes, as the eighth seed rallied from 3-0 down in the tiebreak to take the frame with her third set point.
The second set was more dominant, with Kasatkina claiming it in 35 minutes, although it included five straight broken games. Kasatkina converted her first match point from another Gauff error.
BREAK POINTS WON
Kasatkina - 6/10
Gauff - 5/8
ACES/DOUBLE FAULTS
Kasatkina - 2/2
Gauff - 1/2
WINNERS/UNFORCED ERRORS
Kasatkina - 10/10
Gauff - 25/34
