His first opponent, John Millman, had caused an upset at last year's US Open to put out Federer in the fourth round.
World number four Alexander Zverev's quest for a first title at the Halle Open came to a grinding halt as the two-times runner-up was stunned 3-6 6-1 7-6 (3) by David Goffin in the quarter-finals on Friday.
The world No 3 will set a personal record of lifting a 10th trophy at a tour-level event for the first time in his career if he wins the title on Sunday.
Frenchman Pierre-Hugues Herbert, a grand slam victor in doubles who was targeting the ultimate grass-court singles scalp, proved no match for the Swiss master and fell to a 6-3 6-3 defeat.
Victory was confirmed by another break, this time Federer wrong-footing Herbert with a cross-court forehand. I'm playing well, more aggressive.so, it's a great feeling this week to be in the final'.
The 20-time Grand Slam champion has now reached the last four in each of his last 15 appearances at Halle since losing to Pat Rafter in the 2001 quarters. "I didn't play so much tennis, so I hope to mobilise some extra energy".
"I get another chance after last year's loss against Coric, because after my loss here last year I didn't know if I was going to ever be in another Halle final".
Roger Federer cruised through to the Halle Open final with a ruthless victory over Andy Murray's new Wimbledon doubles partner. I played well from the start. "I'm not surprised about the tough match and enjoyed the battle".
Goffin has lost seven of his eight meetings with Federer in the past, beating him in three sets at the 2017 ATP Finals in London.
Clearly, he had recovered very well from the Tsonga and Bautista Agut tussles, and Federer soon laid out his credentials with a break in the second game.
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