The work presented in this report consists of a compilation of individual activity reports sent to BSC at the conclusion of the FY04 fiscal year. A chapter is dedicated for each individual activity, and describes the accomplishments at the time of writing the original reports, and includes experimental data when appropriate. It is important to note that since work for most of the activities was intended for completion in FY05, no DTN numbers are given in the present report and the results presented here are to be considered preliminary at the time of their writing. Information and results presented in the FY05 Summary Report (UCRL-TR-217339) are more comprehensive and complete and supersede those given in the present report. The five activities addressed in this report are: (1) Preliminary evaluation of burnished and peened samples-metallurgy; (2) Preliminary heat-to-heat variability study-metallurgical; (3) Evaluation of FY00 mockup samples-metallurgy; (4) Weld stability with thick prototypical welds; and (5) Effect of solution annealing onweld metallurgy.