YEARS

TrendsTrends inin LithiumLithium--ionion BatteriesBatteries forfor AerospaceAerospace ApplicationsApplications Features, Performance, Research, & Development NASA Battery Workshop, Marshall Space Flight Center 27 November 2007

David Gallup Manager, Li-ion Space Systems Yardney Technical Products, Inc. / Lithion 860-599-1100 x494

82 Mechanic Street, Pawcatuck, CT 06379 www.yardney.com www.lithion.com Objectives of Presentation

• Overview of Yardney-Lithion battery heritage, developments, applications, performance, & research • Overview of successful results of YTP’s Li-ion Domestic Source Program Yardney Space Heritage

Spacecraft Customer Launcher Launch Date

Mars Lander NASA/JPL No launch, but battery N/A fully tested & qualified MER Rover Spirit NASA/JPL Delta II June ‘03

MER Rover NASA/JPL Delta II July ‘03 Opportunity XSS-11 Lockheed Martin Minotaur April ‘05

X-37 NASA/AF Atmospheric Demo Various

MISSE 5 NRL STS July ‘05

STP-R1 General Dynamics Minotaur Sept ‘05

MiTEx Lockheed Martin Delta II June ‘06 Yardney Space Heritage

Spacecraft Customer Launcher Launch Date

TacSat 2 Broadreach Eng Minotaur Dec ‘06 /AFRL Orbital Express Ball Aero Atlas V March ‘07 NEXTSat Orbital Express Boeing Atlas V March ‘07 ASTRO Phoenix Lockheed Martin/JPL Delta II August ‘07

Planned Launches

BBP Boeing Not Specified Not Specified

IBEX NASA/GSFC Pegasus 2008

Mars Science Lab NASA/JPL Delta IV/Atlas V 2009 NASA/JPL MER Rover Mission

2 x 28V, 10 Ah Lithium Ion Batteries

• Spirit and Opportunity Energy Storage - Nighttime Power Source - Daytime Augmentation During Peak Loads - Design to Test in Nine Months

• Program Extended Multiple Times - Initial Three Month Run-Time Requirement - Operating since Jan 04 – nominal performance Orbital Express Program

30Ah, 28V Li-Ion Battery - NEXTSat (BATC) 43 Ah, 28V Li-Ion Battery - ASTRO (Boeing) • DARPA Technology Demonstration – Validate the Feasibility of Autonomous Robotic Refueling and Reconfiguration – Selective Electronics for Cell Balancing (Automatic/Remote Activated) – Mission to swap NEXTSat Operational Replacement battery from one vehicle to another Boeing 43Ah ASTRO • Launched 8 March 2007 BATC 30 Ah NEXTSat NASA/JPL Phoenix Program

Dual 28 Volt, 30 Ah Lithium-ion Battery System „ Program resurrected from 2001 Mars Lander – Martian Arctic Explorer - Fixed Lander • Determine whether Life ever arose on Mars • Characterize the Climate of Mars • Characterize the Geology of Mars • Prepare for Human Exploration

„ Identical Design as Heritage Battery

„ Customer -- Lockheed Martin Space Systems

„ Launched - Aug 2007 Land - May 2008 NASA/JPL Mars Science Laboratory

2 x 28V, 20Ah Lithium-ion Batteries Design •Retain MER heritage Science •New Li-ion cell - scaled up version • Did/does Mars have of MER cell environmental conditions •20 Ah Nameplate capacity favorable to microbial life? •8S/2P Configuration • Launch schedule: Fall ‘09 •Chemistry identical to MER •JPL low temp electrolyte •No solar arrays – uses radioisotope power source

2009 MSL Rover 2005 MINI Cooper S Design Concept The Look Ahead

„ Lithium-ion Batteries becoming baseline design –Increasing battery power –Increasing battery voltage –Improving cell capacities –Improving life performance –Improving design features High Power Batteries „ Comprised of (40) NCP55-2 cells in (8) series packs of (5) parallel cells (nom. 300Ah capacity) „ Voltage Range 24V to 34V „ Continuous Discharge 100A (C/3) High Voltage Batteries

„ Comprised of (42) NCP12-2 cells in series (nom 12Ah) „ Voltage range 126V to 172V „ Peak Discharge capability 72A (6C) Cell Capacities Increasing „ Process improvements leading to performance improvements Cell Capacities Increasing „ Process improvements leading to performance improvements

4.2

4.1

4.0 Increase in NCP43-2 Cell Capacity

3.9

3.8

3.7 NCP43-2-321 3.6 lts NCP43-2-480

Vo 3.5 48.27Ah 3.4 3.3 3% BOL capacity growth 3.2 over 15 months 46.67Ah 3.1

3.0

2.9 0246810121416182022242628303234363840424446485052 Amp-Hours Cell Capacities Increasing „ Process improvements leading to performance improvements

4.2

4.1

4.0 Increase in NCP43-2 Cell Capacity

3.9

3.8 4.2 3.7 4.1 NCP43-2-321 3.6 Increase in NCP12-2 Cell Capacity lts NCP43-2-480 4.0

Vo 3.5 48.27Ah 3.9 3.4 3.8 3.3 3% BOL capacity growth 3.7 3.2 NCP12-2-476 over 15 months 46.67Ah s 3.6 NCP12-2-985 3.1 t

Vol 3.5 3.0 13.60Ah 3.4 2.9 0246810121416182022242628303234363840424446485052 3.3 6% BOL capacity growth Amp-Hours 3.2 over 18 months 12.85A 3.1

3.0

2.9 0123456789101112131415 Amp-hours Cell LEO Cycle Testing Linear regression modeling predicts cell EOL (3.0V) at ~ 53,000 cycles (3.7V) and ~ 166,000 cycles (3.9V)

LEO Cycling with NCP20 Cells (C/2 Discharge to 20% DOD) 3.6 End of Discharge Voltage

3.5 y = -3E-06x + 3.4981

e 2 g

a R = 0.8519 lt 3.4 rge Vo

a 3.3 h sc i

D y = -6E-06x + 3.319 3.2 R2 = 0.8014 End of X315 LEO to 3.9V 3.1 X325 LEO to 3.7V Linear (X325 LEO to 3.7V) Linear (X315 LEO to 3.9V) 3.0 0 2 4 6 8 1 1 1 1 1 2 2 2 2 2 3 3 3 3 00 00 00 00 00 20 40 60 80 00 20 40 60 80 00 20 40 60 0 0 0 0 00 00 00 00 00 00 00 00 00 00 00 00 00 00 Cycle number HV Battery LEO Cycle Testing At a battery lower limit of 126V, the battery linear regression model predicts

XEOL ≈ 35,200 cycles (8% DOD).

12Ah / 150V Battery Life Cycle Test Results End-of-Discharge Voltage 170

165

160 )

s 155 t

ol y = -0.0011x + 164.77

(V 150 R2 = 0.7713 age t 145 Vol

y 140 er tt a

B 135

130

125

120 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 Cycle Number HV Battery LEO Cycle Testing At a lower limit of 3V, the cell linear regression model predicts

XEOL≈ 30,700 cycles (8% DOD).

12Ah / 150V Battery Life Cycle Test Results End-of-Discharge Voltage (cells) 4.00

3.90

3.80

3.70

) y = -3E-05x + 3.9218 ts

l 3.60 R2 = 0.876 3.50 e (Vo g

3.40 Volta 3.30 Cell

3.20

3.10

3.00

2.90 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 Cycle Number LV Battery LEO Cycle Testing At a battery lower limit of 24V, the battery linear regression model predicts

XEOL ≈ 32,800 cycles (20% DOD).

43Ah / 28V Battery Life Cycle Test Results End-of-Discharge Voltage 32.0 31.5 31.0 30.5 30.0 29.5 ts) l 29.0 y = -0.0002x + 30.568 o

V 28.5 2 ( R = 0.8524 e 28.0

ltag 27.5 27.0 26.5 ery Vo 26.0

Batt 25.5 25.0 24.5 24.0 23.5 23.0 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 Cycle Number LV Battery LEO Cycle Testing At a lower limit of 3V, the cell linear regression model forecasts

XEOL ≈ 27,300 cycles (20% DOD).

43Ah / 28V Battery Life Cycle Test Results, End-of-Discharge Voltage (cells) 3.90

3.80

3.70

3.60 ) y = -3E-05x + 3.8184 olts 3.50 R2 = 0.8987 e (V 3.40 ag t l

Vo 3.30

Cell 3.20

3.10

3.00

2.90 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 Cycle Number Electronics Externalization

„ Modular Electronics „ Used with battery dummy for acceptance testing „ Simplified EMI protection „ Lends itself to rapid field replacement, eliminating need for depot-level service Electronics Research & Development

„ Issues of: – Time & expense to develop unique electronics for different battery applications – Availability of certified space-grade electronics components for Space and Aerospace Applications. Electronics Research & Development

„ Issues of: – Time & expense to develop unique electronics for different battery applications – Availability of certified space-grade electronics components for Space and Aerospace Applications. „ Significant Impacts on: – Schedule (12+ months for certain key components) – High Costs – NRE, component qualification Electronics Research & Development

„ Issues of: – Time & expense to develop unique electronics for different battery applications – Availability of certified space-grade electronics components for Space and Aerospace Applications. „ Significant Impacts on: – Schedule (12+ months for certain key components) – Cost (high demand + scarce supply = high cost) „ These are industry-wide issues and impacts which affect all suppliers and consumers Electronics Research & Development

„ Yardney Electronics Development Program – Significant expansion of in-house Electronics Development Group to bring engineering inside for increased control and flexibility Electronics Research & Development

„ Yardney Electronics Development Program – Significant expansion of in-house Electronics Development Group to bring engineering inside for increased control and flexibility – Assess commonality between applications to identify ways to streamline development of electronics packages Electronics Research & Development

„ Yardney Electronics Development Program – Significant expansion of in-house Electronics Development Group to bring engineering inside for increased control and flexibility – Assess commonality between applications to identify ways to streamline development of electronics packages – Development of “standard” design to reduce recurring costs and improve deliveries Electronics Research & Development

„ Yardney Electronics Development Program – Significant expansion of in-house Electronics Development Group to bring engineering inside for increased control and flexibility – Assess commonality between applications to identify ways to streamline development of electronics packages – Development of “standard” design to reduce recurring costs and improve deliveries – Continuing efforts to resolve supply chain issues Materials Research: Active Materials Domestic Source Program

„ Overseas source of supply for premium quality specially formulated Li-ion active materials lost for all aerospace battery vendors – Business decision to focus on much larger & less demanding mass market apps (cell phones, laptops, etc.) – Leaves aerospace battery vendors & customers at risk » If materials are unavailable » If formulation standards can change without control Materials Research: Active Materials Domestic Source Program

„ YTP-Lithion aggressive proactive program: – Stockpile of original overseas source material » Procured large supply of original active material in anticipation of supply cutoff Materials Research: Active Materials Domestic Source Program

„ YTP-Lithion aggressive proactive program: – Stockpile of original overseas source material » Procured large supply of original active material in anticipation of supply cutoff – Development of new domestic source, focusing on high-power and high-energy needs of aerospace applications beyond LEO satellite needs Materials Research: Active Materials Domestic Source Program

„ YTP-Lithion aggressive proactive program: – Stockpile of original overseas source material » Procured large supply of original active material in anticipation of supply cutoff – Development of new domestic source, focusing on high-power and high-energy needs of aerospace applications beyond LEO satellite needs » Strategic partnership with BASF Materials Research: Active Materials Domestic Source Program

„ YTP-Lithion aggressive proactive program: – Stockpile of original overseas source material » Procured large supply of original active material in anticipation of supply cutoff – Development of new domestic source, focusing on high-power and high-energy needs of aerospace applications beyond LEO satellite needs » Strategic partnership with BASF » Extensive testing shows enhanced rate capability and comparable cycle life Materials Research: Active Materials Domestic Source Program

„ YTP-Lithion aggressive proactive program: – Stockpile of original overseas source material » Procured large supply of original active material in anticipation of supply cutoff – Development of new domestic source, focusing on high-power and high-energy needs of aerospace applications beyond LEO satellite needs » Strategic partnership with BASF » Extensive testing shows enhanced rate capability and comparable cycle life » Guaranteed 10-year source availability of metal oxide cathode material Materials Research: Active Materials Domestic Source Program „ Current Activities – Proceeding with integration/certification in current programs with cells using this new domestic source material in several ongoing aircraft and undersea battery programs Materials Research: Active Materials Domestic Source Program „ Current Activities – Proceeding with integration/certification in current programs with cells using this new domestic source material in several ongoing aircraft and undersea battery programs – Running test programs to demonstrate LEO satellite performance Materials Research: Active Materials Domestic Source Program „ Current Activities – Proceeding with integration / certification in current programs with cells using this new domestic source material in several ongoing aircraft and undersea battery programs – Running test programs to demonstrate LEO satellite performance „ Continuing Improvement – Evaluating numerous process/product enhancements – Mixed-chemistry surface treatments to reduce oxidation Materials Research: Active Materials Domestic Source Program „ Current Activities – Proceeding with integration / certification in current programs with cells using this new domestic source material in several ongoing aircraft and undersea battery programs – Running test programs to demonstrate LEO satellite performance „ Continuing Improvement – Evaluating numerous process/product enhancements – Mixed-chemistry surface treatments to reduce oxidation „ New material has good potential to become baseline for all Yardney aerospace and military programs Opportunity and Spirit continue to explore Mars after 1000+ Sols. Batteries in both vehicles continue to perform very well. Congratulations and Thanks to Lithion for a job well done. Now… on to Mars Science Laboratory! JPL/MSL Kickoff Mtg – 21 Nov 06

Mars Science Laboratory Design Concept