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According to the demand of remanufacturing engine crankshaft, use the automatic high velocity arc spraying system based on the six degree freedom robot, employed the self-design FeNiCrAl wire and ‘circular’, ‘Z’ spraying path for remanufacturing the worn failure crankshaft. Compared with the conventional 3Cr13 coating performance, the residual stress of FeNiCrAl coating was the agreement of the results with the new crankshaft, the bend fatigue performance of spraying FeNiCrAl coated crankshaft conducted accordance with the national standard QC-T637-2000 (test bending moment was 2305.38 N.m, load factor was 1.2, the fatigue life was exceeded 1×107) meet the demand of national standard. The results show that the bend fatigue of FeNiCrAl coated crankshaft was higher than that sprayed by 3Cr13. The remanufacture benefit show that the weights exhaust of FeNiCrAl spraying cored wire was not less than 3% to that product a new crankshaft. The cost of remanufactured a single crankshaft was fell by 90% compared with products a new one. The remanufacturing process saves time about 18% compared to the manufacture a new one. Therefore, the energy saving and environmental protection of the technology is obvious, and the application prospect is broad.