In order to obtain aluminum bronze coating with excellent coating quality on cast aluminum surface by High Velocity Oxygen Fuel spraying technology, the effects of kerosene flux, oxygen flux, powder feeding rate and spraying distance on coating thickness, porosity, microhardness and bonding strength are studied based on orthogonal experiment. The phase composition of the spray powder and coatings is analyzed by XRD. The cross-section morphology of the coating is observed by SEM, and the coating thickness is measured. The porosity is measured by ImageJ. The microhardness and bonding strength of the coating are measured by micro hardness tester and electronic universal testing machine. Range analysis method is used to analyze the results of orthogonal experiment to determine the optimal process parameters. It is obtained by range analysis that the optimal process parameters are kerosene flux 22 L/h, the oxygen flux 900 L/min, the powder feeding rate 80 g/min, and the spraying distance 200 mm. The coating thickness is 405.43 μm, the porosity is 0.10%, the bonding strength is 61.63 MPa, and the microhardness is 330.3 HV0.3 when the optimal process is adopted. The results show that the phase composition of the spray powder and coating is the same, both of which are α phase and β‘ phase. According to the range analysis table, different process parameters have different effects on the porosity, thickness, microhardness and bonding strength of the coating. The powder feeding rate has the greatest influence on the coating thickness and porosity, the spraying distance has the greatest influence on the micro hardness of the coating, and the kerosene flux has the greatest influence on the bonding strength.