Denis Shapovalov hung on and hung on but in the end it wasn't enough Saturday night in Montreal. Here's what went on.
But Federer, a three-time victor of the tournament, recovered to seal a last-eight clash against Roberto Bautista Agut.
Shapovalov has taken major strides this week to reach his goal of cracking the world's top 100 with wins over Rogerio Dutra Silva and 2009 U.S. Open champion Juan Martin Del Potro.
Shapovalov double-faulted as he crumbled for the first time, handing Zverev a 5-4 lead, and the German served out the set.
It was an even contest in the first set, Shapovalov and Zverev going toe-to-toe until the ninth game.
Unlike the match against Ferrer, in which he made a lot of unforced errors before managing a 4-6,6-4, 6-2 win, Federer was in complete control while decimating Agut.
By the time the breezy 6-4, 6-4 win came to a close, Federer had won 81 percent of the first-service points and 50 percent of his break-point opportunities.
Federer finally began to hit his spots on serve, while tightening up his game from the back of the court.
Federer's defeat of Bautista Agut was his seventh in a row without a defeat - or loss of a set - in the series with the Spaniard.
Zverev éteint Shapovalov et rejoint Federer
L'autre demi-finale opposera le Suisse Roger Federer , N.3 mondial, au Néerlandais Robin Haase (ATP 52). Pour rappel, il a bénéficié d'une invitation de la part des organisateurs du tournoi.
Roger Federer of Switzerland reacts after defeating Roberto Bautista Agut of Spain (not pictured) during the Rogers Cup tennis tournament at Uniprix Stadium, in Montreal, Quebec, Canada, on Aug 11, 2017.
Federer is 17-0 in his career against the 35-year-old Ferrer, who was ranked third in the world in 2013 but is now at No.33.
Shapovalov put Mannarino in trouble with a big serve at 30-30, but he rushed an overhead to give the Frenchman the break point.
With little to choose between the payers, it was to be Hasse who would blink first in the opening set, and in the most crucial of games at 5-4 down. But Mannarino got that one back in the next game.
Having performed so admirably to force a tie-break, Haase started slowly but again showed his character by winning four points in a row from 4-1 down. The clay king is looking to reclaim his No. 1 ranking in ATP by winning this year's Roger Cup.
However, it will be an uphill task for Haase in the semi-final, given Federer commanding display at the hard court tournament so far.
The junior Wimbledon victor and tournament wild card entered the week with three ATP-level wins and has added four more so far. The top seeded Nadal and second seeded Federer cruised through their matches on Wednesday.
However, as great champions usually do, the Swiss improved as the match went on and found a way to win.
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