This proceedings volume representing the second International Thermal Spray Conference (May 2004, Osaka, Japan) contains 232 papers and 93 poster presentations. Arrangement is in sections on applications, characterization methods for coating properties, coating technologies for vehicle engines, cold spray, consumables for thermal spraying, corrosion protection, economics and quality, HVOF processes and materials, innovative equipment and process technology, modeling and simulation, nanostructured materials, photocatalytic materials, process diagnostics, protective coatings against wear and erosion, and thermal barrier coatings.