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It's never happened before. But both are in the quarterfinals, one win away a piece from squaring off in the US Open for the first time. Looked up the Nadal vs Federer head to head record:
Nadal - 23 wins (63%)
Federer - 14 wins (38%)
So clearly Nadal has the head to head edge. But then again, in 2017 it's been all Federer. He won when the 2 meet up at the Australian Open in January. And then 2 other times at lesser ATP tournaments. All 3 were on hard court surfaces, same as the US Open court.
Looking at it another way still, Federer has won the US Open 5 times (2004-2008), but none sense. Nadal only took the crown twice, but in 2010 and 2013. So much more recently.
Very interesting matchup between arguably the 2 best tennis players in the world, if it happens. My guess is it will. Any guess as to who takes it?