Playing under the lights at Arthur Ashe Stadium, the 55th-ranked Rogers rallied from a 5-2 deficit in the third set to stun the Wimbledon champion and advance to a fourth round meeting with Emma Raducanu.
Rogers produces stunning rally to shock Barty
Rogers drew first blood in the third game of the match as Barty committed back-to-back double faults to give the American a 2-1 lead. With some solid work on serve, she consolidated her advantage and broke for a second time.
Serving for the set leading 5-2, a serve-forehand combination brought up double set point and a jamming serve forced a weak reply from Barty as Rogers took the lead, sensing an upset was possible.
The second set saw a complete reversal as Barty cranked a forehand winner to break Rogers and take a 3-1 lead. A backhand error padded the Australian's lead and on double set point, she fired off a big serve to force a third set.
A long game in the deciding set saw the top seed break and after holding steadily throughout, some deep hitting forced a forehand long from Rogers and Barty had a second break and a seemingly insurmountable 5-2 lead.
That's when the American began her comeback, retrieving one break and after coming through a tough service game, a wayward forehand by Barty brought Rogers level. Each woman held and a tiebreaker was needed.
The deciding point was at 5-5, a Barty error giving Rogers a match point and a big serve out wide did the job as the world number 43 recorded the biggest victory of her career.