The work aims to study crack propagation behavior in different shape and size in the remanufactured coating. Cracks in the coating layers subject to three-point bending test and tensile test were simulated and validated by experiment by setting fracture energy G value as parameter for controlling cracks by combining extended finite element method and cohesive element method. As the load increased, vertical crack and 45° inclined crack in the coating extended along coating thickness. The cracks deflected at the interface and further extended along the interface without extending toward the substrate over the coating-substrate. Simulation showed that critical load at which vertical crack and 45° inclined crack with initial crack length of 0.2 mm under the three-point bending test were acquired were 3.47 kN and 4.49 kN, respectively. When the crack length increased to 0.3 mm, the critical load was reduced to 3.29 kN and 4.31 kN. The closer the crack was to the center line of the test piece, the lower the critical load was, the more prone to crack propagation would be. On the other hand, under the tensile test, critical crack load of the 0.2 mm vertical crack (3.47 kN) was less than that of the same inclination crack of the same projection length (5.21 kN), and the crack parallel to tensile stress did not expand. The experiment showed that average critical load of 0.2 mm vertical crack under bending test was 3.49 kN, and for inclined crack, 4.46 kN. Under the three-point bending test, vertical crack is more dangerous than inclined crack. Cracks of longer initial length closer to testpiece center are more likely to be subject to crack propagation. The crack parallel to the tensile stress does not expand under tensile experiment, which is the safest. The simulation results are close to the experiment results, and simulation correctness is verified.