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Fabrication and Testing of DOE Standard Canister Closure Leak Test Assembly – 24139

DOE manages over 300 types of spent nuclear fuel (SNF), many of which are located at the Idaho National Laboratory (INL) site. Managing this large variety of SNF for storage, transportation, and disposal poses a challenge to DOE. The Idaho Cleanup Project and INL are collaborating on the DOE SNF Road-Ready Demonstration (“Road-Ready Demonstration”), which will develop and demonstrate the designs, technology, processes, and regulatory framework for packaging DOE-managed SNF for “road-ready dry storage.” Road-ready dry storage is an SNF management concept in which SNF is packaged into dry, sealed canisters that are then placed in onsite storage in anticipation of later transport and disposition. The forward-looking goal of the Road-Ready Demonstration is to establish the foundation for a large-scale road-ready dry storage program at the INL site. In support of establishing a large-scale road-ready dry storage program at the INL site, the Road-Ready Demonstration will first package Fort St. Vrain SNF currently in dry storage at INL into several DOE Standard Canisters (DOESCs). These DOESCs will in turn be loaded into another containment similar to commercial multi-purpose canisters. This multi-purpose canister will then be compatible with a transportation or storage system, such as a storage cask for interim storage or transportation package for offsite transport. These DOESCs will remain sealed over the course of their storage, transportation, and applicable disposal functions. The closure process for the DOESC will include fuel and basket loading, welding, inspection, leak testing, and, if needed, repair. As a follow-up to previous discussions on the design of the DOE Closure Leak Test Assembly (LTA), this report describes recent fabrication and testing efforts performed at INL. DOESCs are sealed by two sequential gas tungsten arc welds, both of which are performed by remotely operated and semiautomatic welding systems. The first weld is a circumferential pipe weld that completes the assembly of the canister body and lid assembly. The second and final closure weld attaches the vent plug to the vent socket via a butt joint. After the second weld is performed, the welds are helium leak tested using an evacuated envelope technique. The LTA was designed for both remote and manual operation. This report describes the fabrication and performance testing associated with the evacuated envelope technique. INL staff designed, fabricated, and tested the LTA at INL facilities. This testing included establishing technique and system sensitivities in accordance with ASME and American National Standards Institute N14.5 requirements. Forthcoming work will cover such areas as design optimization, process and personnel qualification, and implementation in Road-Ready Demonstration operations.

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DOE SNF Packaging Demonstration Project: Worktable and Canister Loading Sleeve Design [Slides]

This presentation is a briefing for summer interns and others outside the project, to give them a summary of ongoing design activities. The DOE SNF Packaging Demonstration Project is an effort to develop and demonstrate the designs, technology, processes, and regulatory framework for packaging DOE-managed spent nuclear fuel (SNF) for road ready dry storage (RRDS). The project is to remotely load and seal two types of DOE-managed SNF from the CPP-603 facility into DOE Standard Canisters, place the sealed DOE Standard Canisters into commercial vendor over-canisters (equivalent to commercial MPCs), seal and place the over-canisters into commercial vendor storage overpacks, and place the storage system (over-canister and storage overpack) onto the CPP-2707 cask pad.

42 ENGINEERING↗

DOE Standard Canister Loading Methodology Poster

Over 250 different types of spent nuclear fuel (SNF) are managed by the U.S. Department of Energy (DOE) at the Idaho National Laboratory (INL). The current configuration of SNF at INL is not transportable off-site. In the Yucca Mountain Repository License Application, the SNF was to be loaded into DOE Standard Canisters which are capable of storage, transportation, and eventual disposal using the proper overpacks. The DOE Standard Canister will allow INL to place the SNF in a Road-Ready configuration in preparation for transportation off-site. The focus of this work is development of a general loading methodology for the DOE Standard Canister. This methodology is to be general enough that it will apply to all SNF to be loaded into the DOE Standard Canister. The main sections of the methodology to be outlined are prerequisites before loading (including any issues with materials such as inserts or baskets), loading of SNF, and canister closure and quality assurance (including welding and inspection). Each subsection will analyze and provide the bases for each step.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Panel Session 94: US DOE Procurement Opportunities and End-State Contracting Model Status

This panel focused on DoE's procurement implementation strategy and planned activities for its first-tier contractors (Tier 1 procurements). This panel also focused on the implementation status of DoE's End State Contracting Model, which uses a single-award ID/IQ approach to give DOE flexibility to better define discrete scopes of work for site closure or end states. The panelists provided their prospective on progress toward the implementation of this new approach, lessons learned and the path forward for upcoming opportunities utilizing this contracting model. Panelists with presentations: EFCOG (Billy Morrison); DOE Procurement Opportunities - 4 Ways for Small Business Participation (Anne Marie Bird); US DOE Procurement and Contracting Opportunities (Aaron Deckard)

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Panel Session 90: US DOE Mixed Waste: Proposals for Dealing with Problematic Waste Streams and Policy Changes

This panel focused on generation and management of low level and mixed low-level radioactive wastes, challenges for disposition, innovative solutions applied at DOE sites, and collaboration among sites to ensure that waste disposition pathways are understood. In addition, potential policy initiatives were discussed including depleted uranium, elemental mercury, and treatment of legacy mixed waste components. As part of the introduction, Theresa Kliczewski provided an overview of why this panel is relevant: problematic mixed waste streams still exist across the DOE cleanup complex. Theresa noted that the DOE EM Headquarters Office of Waste and Materials Management (EM-4.2), for which she is employed with, continues to work with the DOE cleanup sites on a path forward for these problematic mixed waste streams. As part of this effort, EM-4.2 requested that the Energy Facility Contractors Group (EFCOG) perform a review of all the DOE sites problematic mixed waste streams. Panelists with presentations: Challenging Waste Streams: Disposition of Depleted Uranium Oxide Conversion Product (Douglas Tonkay); EFCOG WMWG Challenging Waste Subgroup (Tammy Monday); Mercury Waste Challenges (John Wrapp); Legacy Large Mixed Waste Components (Kalli Shupe)

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AI@DOE Interim Executive Report

Interim executive report for DOE’s Office of Science, NNSA, and Applied Energy Offices, in collaboration with the Artificial Intelligence and Technology Office, DOE AI roundtable workshops (December 2021 through February 2022) (“AI@DOE”). These workshops were used to help identify AI research requirements and priorities for the next decade for Department of Energy in developing machine-learning-based prediction and decision-support capabilities that address and anticipate DOE mission challenges. These missions’ challenges for AI include: AI to advance scientific discovery and technological innovation AI to support high consequence decisions while managing risk AI to improve DOE’s responsiveness to national & global issues AI to assist stewardship of the environment and national critical infrastructure These will be addressed in large part through the development and application of new and powerful artificial intelligence and/or machine learning algorithms and strategies. https://web.cvent.com/event/fc3922f8-fc75-4041-a317-f13a1da44f7c/summary?locale=en-US&i=2Wx2tjbStkydRFq_N2whPw

97 MATHEMATICS AND COMPUTING↗

DOE Data Days 2023 Report

The DOE Data Days (D3) workshop brings together data managers, developers, researchers, and program managers across the Department of Energy (DOE) and national laboratories to highlight data management successes, identify potential synergies and common problems, and establish channels for collaboration across the DOE data management community. The fourth D3 workshop was held on October 24th to 26th, 2023 held entirely in-person at Lawrence Livermore National Laboratory (LLNL). The workshop was organized by a multi laboratory committee in an effort to bring data management practitioners at the DOE laboratories together to share their work and results, facilitating knowledge transfers and best practices across project teams. Tools and platforms to support data management and analysis are rapidly evolving and provide enormous opportunities. This report summarizes the important discussions and recommendations from the different working sessions and contains the agenda, submitted abstracts, presentations with links to recorded presentations, breakout session summaries, list of registered attendees, and lessons learned for future organizing committee. The report will be distributed to the DOE, each participating institution’s programmatic stakeholders, and attendees. The dedicated D3 website will host presentations, agenda, and report that is accessible by all labs.

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Final DOE-ASR Report for the Project “Using LASSO to bridge the gap between model and observations and to learn about atmospheric convection”

Atmospheric convection spans a wide range of spatial and temporal scales and involves complex interactions with the surrounding dynamic and thermodynamic environment, particularly over tropical continental regions. These processes remain a major source of uncertainty in weather and climate models, including persistent biases in the diurnal cycle of convective precipitation that directly affect estimates of climate sensitivity. Addressing these challenges requires the combined use of high-resolution observations and cloud-resolving modeling frameworks. In this context, the DOE Atmospheric Radiation Measurement (ARM) program’s Large-Eddy Simulation ARM Symbiotic Simulation and Observation (LASSO) activity provides a powerful platform that pairs comprehensive observations with numerical simulations to enable process-level understanding of atmospheric convection. Within this context, this Research and Development Partnership Pilot (RDPP) project was designed to initiate and expand DOE ARM/ASR research capacity at minority-serving institutions, while advancing scientific understanding of convective processes over the Amazon rainforest. Consistent with the RDPP mission, the project emphasized partnership development, training, and workforce capacity building alongside exploratory research activities. On the scientific side, the project produced two peer-reviewed journal articles, and one manuscript currently under review (see list in section 3.1). Together, these studies combine long-term ARM observations and cloud-resolving and convection-permitting modeling to investigate the environmental controls on the shallow-to-deep convective transition during the Amazon wet season. The results demonstrate the central role of early-day moisture preconditioning and large-scale dynamical forcing in regulating isolated deep convection, provide mechanistic insight into convective evolution, and establish physically informed modeling frameworks for future sensitivity experiments. These scientific outcomes are described in sections 2.1 to 2.3 and were disseminated in 8 conference presentations (see section 3.2) and 5 invited talks (see section 3.3), reflecting broad engagement with our community. Equally important, the project achieved its RDPP capacity-building objectives (see section 2.4). A sustained research partnership was established among the University of Maryland, Baltimore County (UMBC), Morgan State University (MSU), and Howard University (HU), and extended to include collaboration with Pacific Northwest National Laboratory (PNNL). The project organized multiple multi-day training events focused on ARM data, LASSO simulations, and quantitative analysis methods, directly engaging students, postdoctoral researchers, and faculty across institutions. These activities broadened participation in ASR research and led to independent adoption of LASSO workflows by students beyond the immediate project team. Finally, the project successfully positioned the participating institutions to pursue future DOE research. Preliminary scientific results, coupled with strengthened partnerships and technical capacity, enabled the submission of follow-on proposals to DOE ASR funding opportunities. In this way, the project fulfilled the RDPP goal of seeding durable research capacity and laying the foundation for larger-scale, sustained engagement with DOE ARM and ASR programs.

54 ENVIRONMENTAL SCIENCES↗

Opportunities for DOE National Laboratory-led QuantISED Experiments

A subset of QuantISED Sensor PIs met virtually on May 26, 2020 to discuss a response to a charge by the DOE Office of High Energy Physics. In this document, we summarize the QuantISED sensor community discussion, including a consideration of HEP science enabled by quantum sensors, describing the distinction between Quantum 1.0 and Quantum 2.0, and discussing synergies/complementarity with the new DOE NQI centers and with research supported by other SC offices. Quantum 2.0 advances in sensor technology offer many opportunities and new approaches for HEP experiments. The DOE HEP QuantISED program could support a portfolio of small experiments based on these advances. QuantISED experiments could use sensor technologies that exemplify Quantum 2.0 breakthroughs. They would strive to achieve new HEP science results, while possibly spinning off other domain science applications or serving as pathfinders for future HEP science targets. QuantISED experiments should be led by a DOE laboratory, to take advantage of laboratory technical resources, infrastructure, and expertise in the safe and efficient construction, operation, and review of experiments. The QuantISED PIs emphasized that the quest for HEP science results under the QuantISED program is distinct from the ongoing DOE HEP programs on the energy, intensity, and cosmic frontiers. There is robust evidence for the existence of particles and phenomena beyond the Standard Model, including dark matter, dark energy, quantum gravity, and new physics responsible for neutrino masses, cosmic inflation, and the cosmic preference for matter over antimatter. Where is this physics and how do we find it? The QuantISED program can exploit new capabilities provided by quantum technology to probe these kinds of science questions in new ways and over a broader range of science parameters than can be achieved with conventional techniques.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Preliminary Evaluation of Loading DOE Standard Canisters in the INL CPP-603 Irradiated Fuel Storage Facility - 20543

This paper looks at the equipment and operations necessary to load United States Department of Energy (DOE)-owned Spent Nuclear Fuel (SNF) into DOE Standard Canisters in the CPP-603 Irradiated Fuel Storage Facility (IFSF) in the Idaho Nuclear Technology and Engineering Center (INTEC) area at Idaho National Laboratory (INL). Two types of fuels are looked at in this evaluation: Advanced Test Reactor (ATR) fuel (uranium-aluminide fuel with aluminum cladding) and Peach Bottom fuel (thorium-uranium carbide fuel in a graphite matrix). The fuel ready for loading would come from fuel storage canisters in the CPP-603 facility. The paper describes the facility, the fuel types, the DOE Standard Canisters, and existing equipment; lists the needed loading operations; reviews facility features and equipment to perform the operations; and then lists the decisions, analyses, designs, demonstrations, and modifications that will be needed to perform the loading of DOE-owned SNF into DOE Standard Canisters in the CPP-603 IFSF. (authors)

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Livewire: A Model Platform for Data Quality Assessment and AI Readiness Across DOE Missions

High-quality, well-governed data is essential for accelerating discovery and achieving operational excellence across DOE and national laboratory missions. The Livewire Data Platform is a DOE-supported platform that offers automated assessments of data quality, standardization, provenance, and Artificial Intelligence (AI) readiness. It allows researchers and data practitioners to systematically and easily evaluate datasets against established governance criteria and prepare them for advanced analytics. Livewire addresses critical challenges in DOE's data ecosystem with integrated capabilities for metadata validation, provenance tracking, and schema alignment. This platform's automated workflows assist users in identifying data quality gaps, enhancing interoperability between datasets collected from various stakeholders, and ensuring compliance with DOE data standards, all while reducing manual curation efforts. Additionally, we will discuss its AI readiness framework, which is being developed to prepare datasets for training models, developing advanced analytic tools, and machine learning applications. Using some of the more than one hundred tabular datasets on Livewire, processed with this open-source methodology, we will demonstrate how Livewire can serve as a model for scalable, standards-driven data management. This approach provides a pathway to leverage existing and future datasets within the DOE, boosting innovation and efficiency across national laboratories.

33 - ADVANCED PROPULSION SYSTEMS↗

A Review of Remote Welding and Nondestructive Examination Technologies for the DOE Standard Canister

The U.S. Department of Energy (DOE) manages a wide variety of spent nuclear fuel (SNF) that poses a unique management challenge. To help address this challenge, the DOE Standard Canister (DOESC), designed to remain sealed during handling, storage, transportation, and disposal, was conceptualized as a standardized containment vessel to accommodate DOE-managed SNF. Since 1999, several welding and examination processes have been independently developed for the DOESC’s closure welds. However, neither the DOESC nor these processes have been realized in an operational capacity. This review paper seeks to present and compare previously developed DOESC closure weld, nondestructive examination, and repair processes and technologies. Specific processes developed for the Idaho Spent Fuel Facility, in preparation for the Yucca Mountain geological repository, and the recent Road-Ready Demonstration Project are discussed. Further, specific focus is given to how different operating constraints and the American Society of Mechanical Engineers Boiler and Pressure Vessel Code (BPVC) have driven certain welding and nondestructive examination requirements. Historical DOESC welding and examination strategies are assessed against current regulatory and BPVC requirements. The comparison of welding processes, technologies, and DOESC designs presented in this review paper will inform further construction efforts for other commercial and DOE-managed SNF containments, including the DOESC.

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Summary of US DOE R&D Activities on Graphite Oxidation (2006–2021)

The objective of the international collaboration between United States Department of Energy (U.S.-DOE) and Generation IV International Forum (GIF) is the development of the next generation of nuclear energy systems. The current GIF Project Arrangement (PA) on Materials (2018-2022) was revised in 2019 and extended for another 10 years (2020-2030). The Work Package 1 (“Graphite”) of the extended Project Plan (PP) on Materials specifies technical tasks and High Level Deliverables for research and development (R&D) activities related to using graphite in fuel elements, reflectors, and support structures of Very High Temperature Reactors (VHTR). The graphite tasks include specification and acquisition, qualification and development of new grades, characterization of properties, and development of behavior models. Specifically, Task 1.4 (“Graphite Oxidation Behavior”) outlines planned activities related to acute oxidation by air and chronic oxidation by impurities in the helium coolant. A final report on experimental data regarding graphite oxidation behavior is scheduled for 2022 (deliverable 3.1.1.4.a). In preparation of this deliverable, this document summarizes the R&D activities funded by U.S.-DOE from 2006 (the inception of the VHTR system arrangement) through present (2021). This report is being submitted to the GIF Graphite Working Group (GWG) to serve as input for the GWG high-level deliverable to the Project Management Board (PMB) of PA on Materials. Besides U.S.-DOE, other organizations participating to Task 1.4 of the current PA on Materials are: European Commission’s Joint Research Center (JRC), Korea Atomic Energy Research Institute (KAERI), and Japan Atomic Energy Agency (JAEA). U.S.-DOE is the main contributor on graphite oxidation R&D, with 85 % commitment of total funding during 2018-2022.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Modeling DOE Standard Canister Configurations with Updated Surface Chemistry

Road-ready and final disposition packaging configurations for the advanced test reactor (ATR) fuel currently specifies storage within helium backfilled DOE sealed standard canisters. The aluminum cladding of the ATR fuel contains an oxyhydroxide layer of boehmite/bayerite that generates hydrogen when subjected to irradiation. Understanding the effect of this hydrogen buildup over time to important for long term storage considerations. Previous modeling efforts have built a coupled CFD-chemical model to simulate the temperature gas phase concentrations within the DOE sealed standard canisters. These models have coupled the temperature conditions to both the gas phase radiolysis chemistry and the surface chemistry associated with the oxyhydroxide layer. Continued experimental work has identified trends for aluminum surrogate samples with oxyhydroxide layers for tests done at higher dose rates. At low initial doses a fast generation rate of hydrogen occurs which starts to roll over to a lower generation rate as the total dose applied in increased. A previous study created a small-scale chemical model was built to replicate a mini-canister surrogate system at SRNL as well as for the smaller capsule tests performed at INL. The previous iteration of the model utilized step function for its G-values for the hydrogen generation over a 200-year period. This model makes an update to the surface chemistry to account for theorized surface chemistry reactions allowing for oxygen to remain bounded to the oxyhydroxide layer. As additional experiments continue, the kinetic fits may be adjusted to adapt to new data. Three canister configurations are modeled – the base 18-inch, 15-foot DOR standard canister with 30 ATR fuel elements, an 18-inch, 10-foot DOE standard canister with 32 ATR fuel elements and a 24-inch, 10-foot DOE standard canister with 40 ATR fuel elements. In previous reports, the primary sensitivity of the canister conditions was identified as the decay heat of the fuel and the dried condition of the fuel. Only these parameters are studied in the report. For the nominal case with dried fuel, the hydrogen generation is only about 2%, so it is even less than the flammability limit if it were exposed to oxygen. For the densely packed 18-inch case the total hydrogen concentration is only around 4% with the nominal decay heat. For the densely packed 24-inch case the total hydrogen concentration is only 2.5%, roughly 20% higher than the original packing design, and still under flammability conditions if exposed to oxygen.

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Chemical Modeling of ATR Fuel in DOE Standard Canisters with Borated Stainless Steel Corrosion

Road-ready and final disposition packaging configurations for the ATR fuel dictates storage within helium backfilled sealed DOE standard canisters. The packaging configuration for the DOE canisters places 10 ATR elements within a Type 1a basket, and three baskets are loaded within each DOE canister. In order to provide a criticality control mechanism, these stainless baskets are proposed to be built with 1-2 weight percentage of boron. This report seeks to identify effects of corrosion of this basket material over time. The primary reaction found through surveying literature was the oxidation of the iron in steel by water to produce some hydrogen. This reaction was built into the previous chemical model of the DOE canister to assess additional hydrogen and pressure build up over time. Literature for non-borated stainless steel, and carbon steel has shown that irradiation increases the rate of corrosion, and it is assumed a similar effect would occur with borated stainless steel. Due to the wide range of results in literature, and the variation of the corrosion with boron content, a wide range of corrosion rates was tested in the model from 80 nm/yr up to 1800 nm/yr.

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Technical Basis for Proposed Changes to DOE-STD-1194-2019, Nuclear Material Attractiveness Determination and Categorization

The Department of Energy (DOE)’s Technical Standard DOE-STD-1194-2019 (dated September 2019), Nuclear Materials Control and Accountability, provides key guidance for the determination of Special Nuclear Material (SNM) attractiveness levels. Attractiveness levels are a key component in the security categorization of SNM processed, used, and stored at DOE facilities. Upon review, the writing team identified specific components relating to the determination of attractiveness levels that could be modified to improve clarity, reduce burden on sites, and/or better align with the graded safeguards principle that is central to the DOE’s nuclear security program. The report outlines the original verbiage, issues with implementation of that verbiage, proposed new verbiage, and the expected benefits thus serving as the technical basis for the proposed changes.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗

DOE Challenges and Opportunities Associated with Accountable Nuclear Material Needs for Development and Commercialization of Fusion Nuclear Energy

Fusion energy represents a transformative opportunity to deliver a safe, plentiful, and carbon-free source of reliable primary power. In recent years, fusion research and development have accelerated significantly, particularly within the US, driven by decades of foundational public investment. Notably, in 2024 the US Department of Energy (DOE) established a comprehensive Fusion Energy Strategy aimed at collaborating with industry partners to enable the deployment of fusion power plants and grid integration by the 2030s. This strategy is chiefly implemented through the DOE Office of Science (SC) Fusion Energy Sciences program. This project was initiated to identify potential approaches for the Office of Environment, Safety, and Health (NA-ESH-12) within DOE’s National Nuclear Security Administration to begin engagement with the fusion community on future accountable material needs. The goal of the project is to inform and influence the supply of and demand for accountable nuclear materials as fusion energy is developed and commercialized. NA-ESH-12 must proactively engage with the fusion community regarding the production and management of accountable nuclear materials. Given the complexity and scale of materials required for research, pilot projects, and eventual commercial reactors, early coordination is vital. The project’s objective is to provide insights that will shape the supply and demand landscape for critical nuclear materials, ensuring that DOE is prepared to effectively support fusion energy development and commercialization. In FY 2025, an initial limited review was conducted to identify the status of the fusion energy community’s progress toward full-scale energy production and the need for accountable nuclear material. This included communications with SC, NA-ESH-12, Savannah River National Laboratory, and Oak Ridge National Laboratory, and attending the Rutgers University–sponsored Supply Chain Workshop: Scaling the Fusion Industry and the International Atomic Energy Agency’s Ninth DEMO Programme Workshop. The review to date indicates that the amounts of tritium, lithium-6, and deuterium required by the fusion industry will be dependent on fuel type, breeding technology, blankets, and R&D improvements. One concern is that the commercial sector does not have a sufficient supply chain to meet the demand for development and commercialization for fusion energy production. The supply and demand estimates for these materials should be routinely reviewed as fusion technologies mature.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Panel Session 13: D and D Collaboration Between US DOE EM and NNSA (R6.3)

This panel focused on the interaction and collaboration between US Department of Energy's Office of Environmental Management (DOE EM) and National Nuclear Security Administration (NNSA) offices and sites. Panelists with presentations: NNSA and DOE EM Collaboration on Facility Disposition (Deborah Couchman-Griswold); DOE EM and NNSA D and D Collaboration at the Y-12 National Security Complex (Diane McDaniel); Working Together to Achieve Environmental Cleanup Success in Oak Ridge (Laura Wilkerson, James Daffron); DOE-EM - NNSA (Rick Demmer)

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