The Swiss master stormed to his latest victory - a fourth in as many finals this year - in just 53 minutes and appears in prime form with little more than a week to go until he begins his pursuit of an eighth Wimbledon crown.
The 20-year-old Zverev had no answer to Federer's inch-perfect execution and was broken three times in a lightning-fast first set.
However, 21-year-old Khachanov rallied and force two set points which would have taken the match into a decider before Federer, an 18-time Grand Slam victor, closed out the tie-break.
"I think it was a very good week for me again making the finals here".
Federer progressed in Halle at the expense of Mischa Zverev who he beat in two sets
Petra Kvitova, the two-time Wimbledon champion who is making a courageous comeback from injury, will face unseeded giant-killer Ashleigh Barty in the final of the Birmingham grass court tournament.
"It is a dream to start a final like that and to pull through then". While Federer will be expected to get his ninth title here at the Halle Open, Zverev had proven that he can compete with the best as he defeated Novak Djokovic earlier this year. Zverev created his only break chance in the opening game of the second, but ultimately was unable to show why he is regarded as one of the sport's brightest prospects.
This will be the second meeting between Federer and Zverev in the Halle Open after the latter triumphed in a 7-6, 5-7, 6-3 semi-final win. He has not dropped a set along his way to the finals and also defeated Zverev's older brother Mischa to make this far into the tournament.
But he quickly fell behind in the second as Zverev, a finalist past year, who has already won three titles in 2017, charged to a 4-2 lead and held on to take the set.
Alexander Zverev failed to stop Federer's momentum as the Swiss sewed up the match on his first match ball to reap his 92nd career title.
LaVar just can't let Lonzo enjoy his National Basketball Association draft moment
In their second trade, the Lakers traded the 28th pick to the Utah Jazz in exchange for the 30th and 42nd overall selections. LaVar Ball talked his son Lonzo becoming a Laker into existence, and he might just do the same about next year's playoffs.