Abstract: Aiming at the frequent surface crack, volume damage and high cost of repairing materials for TC4 alloy blades, the FeCrNiB alloy and TiAlVFe were chosen for remanufacture, the surface cracks and volume damage of TC4 blade were remanufactured based on the advantages of pulsed laser forming process, the process matching was verified from the forming process, the metallographic microstructure and three-dimensional size aspects. The results show that the FeCrNiB cladding layer is composed of fine and compact equiaxed crystals, interlaced dendrite and homogeneously distributed cell crystal, while the TC4 alloy is mainly composed of interlaced acicular martensite and basketweave sstructure, both the organization of layers are in better form. The microhardness of the FeCrNiB cladding layer is 380-750 HV0.1, one time higher than the substrate. The microhardness of the TC4 cladding layer is 295-350 HV0.1, which is similar with the substrate. The dimension accuracy of the blade after remanufacture was controlled within 0.8 mm. Through the laser process optimization and performance matching analysis, the FeCrNiB alloy was suitable for local microcrack remanufacture, while the TC4 alloy was suitable for the forming of volume damage.