Top seed Andy Roddick survived a barrage of 29 aces from Ivo Karlovic to earn a semi-final spot in Washington. Roddick fired 19 aces of his own as he beat Karlovic 6-7 (7-9) 7-5 6-4, and he goes on to face Paradorn Srichaphan who beat Luis Horna 6-4 7-5.
"I think he started getting tired in the third set," said Roddick. "I was getting looks at second serves."
In the other semi-final, James Blake of the United States will face the Czech Republic's Tomas Berdych.
Blake advanced to the last four with a 6-3 6-2 rout of France's Arnaud Clement.
The 10th seeded Berdych defeated America's Bobby Reynolds 7-6 (7-5) 7-6 (11-9).