British number one Andy Murray beat the nine-time French Open champion Rafael Nadal 7-5 6-4 in 2 hours 11 minutes to book his spot at the finals.
The 28-year-old Scot will face either Novak Djokovic or Kei Nishikori in Sunday's final at Caja Magica.
Murray is looking to hold on to his world number two ranking, which he will lose to Roger Federer unless he retains his title in Madrid.
Murray, who sent down eight aces and saved 11 of 13 break points, said he was "going back in the right direction again" after losing early in Indian Wells and Miami in March.
"I think it's big - it's not easy. Not loads of players have won against Rafa on clay throughout his career," he said.
"To beat him in Spain on a clay court is obviously a big challenge. It's a big step for me from where I was four or five weeks ago."
Murray established an early lead in the opening set of the semi-final, earning three break points in Nadal's second service game and holding his composure to break the Spaniard.
The momentum appeared to swing Nadal's way when he responded by taking Murray's serve, but it was the Scot who took the first set with a winning forehand that broke the home favourite for a second time.
World number five Nadal, 29, was looking for a third successive tournament victory following wins in Monte Carlo and Barcelona last month.
But Murray followed his only double fault with an ace at 2-2 to hold in the second set before immediately breaking Nadal.
Nadal repelled a first match point with a break of his own, but Murray did not waste a second opportunity to repeat his victory over the same opponent 12 months ago.
The Spaniard believed he "was a little bit unlucky" in the second set but acknowledged that Murray "adapted better than me" to the cool, cloudy conditions, which meant the ball did not bounce as high as he would have liked.
"I think in the first set he played better than me. I think in the second it was a different story," said Nadal.
"I played more aggressive, I increased the intensity and rhythm of the game and had more opportunities than him in the second."
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