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Lightly coat poblanos with cooking spray. Arrange in a single layer in the basket of a 6-quart air fryer. Cook at 400°F, flipping once, until the skins are charred, about 10 to 12 minutes. Transfer to a bowl, cover with plastic wrap and let steam for 10 minutes.
Meanwhile, cook pork, zucchini and onion in a large skillet over medium heat, stirring and breaking up the pork with a wooden spoon, until the pork is cooked through and the zucchini is tender, 5 to 8 minutes.
Add black beans, chili powder, garlic powder, salt and pepper; cook, stirring, for about 2 minutes. Remove from heat and stir in sour cream and cilantro.
Carefully peel the skin from the peppers and cut a slit, lengthwise, down one side of each pepper; remove and discard seeds.
Gently stuff the peppers with the pork mixture. Carefully arrange the peppers in the air-fryer basket (they'll be delicate). Cook at 400°F until heated through, about 5 minutes.
Top the stuffed chiles with cotija. Sprinkle with additional cilantro, if desired. Serve with chips and salsa, if desired.