The big serving German staged an emphatic comeback to turn around a two set deficit and beat his resilient Spaniard and win the semifinal encounter in five tight sets with the scoreline reading 3-6 2-6 6-3 6-4 6-3
Zverev awaits the winner of the second semifinal between second seed Dominic Thiem and third seed Russian Daniil Medvedev in Sunday's grand finale at the Arthur Ashe Stadium.
Austrian second seed Thiem, 27, is taking on Russian third seed Medvedev , who was the losing finalist to Spain's Rafael Nadal in last edition of the US Open at Flushing Meadows.
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Zverev who is known for his booming serves which also happens to be his most potent weapon looked a bit off colour and rustic as he committed a lot of faults on his service and unforced errors, giving his more consistent Spaniard a chance to break him regularly and win the opening two sets. Staring at a potential upset defeat Zverev then raised his game and went onto win the next three sets to seal the five setter contest
"I knew I had to come up with better tennis and be more stable," said a relieved Zverev. "I knew I had to play better, I've never come back from two sets to love but I'm happy to do it at this stage.
"I'm through to my first Grand Slam final and that's all that matters."
The men's singles final at the US Open on Sunday will see a new Grand Slam champion crowned for the first time since the 2014 US Open when Croatia's Marin Cilic won the title.
The pull out of former champions Rafael Nadal and Switzerland's Roger Federer at the first ever behind-closed-doors Grand Slam, and the shocking exit of top seed Novak Djokovic means that one of the promising next Gen players have a great chance of winning their maiden grand slam title