A computational investigation of chaotic saddles in a Duffing vibro-impact system is presented. Chaoctic saddle crisis is investigated in a duffing vibro-impact system considered. This crisis is due to the tangency of the stable and unstable manifolds of period saddle connecting two chaotic saddles. The threshold of tangency induces the merging crisis of chaotic saddle, that is, as the system parameter crosses the critical value, a larger boundary chaotic saddle appears due to the merging of two chaotic saddles located on the basin boundary and in the internal basin respectively. In fact, this chaotic saddle crisis is responsible for the merging crisis of chaotic attractors eventually.