Zverev, the fifth seed, held off a stirring comeback from the 38-year-old who produced some sublime tennis to fend off five match points to send the match to a decider.
However, Zverev, ranked sixth in the world but without a top 10 scalp in 2019, rallied behind his backhand in the third set to open up a 4-1 advantage against an increasingly agitated Federer.
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In fact, such was the Swiss star’s chagrin at his performance and the German's excellence, he was deducted a point in the fourth game of the deciding set and would eventually go down in two hours and six minutes.
Zverev faces Matteo Berrettini for a place in the final after the Italian beat Dominic Thiem 7-6(8) 6-4.
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