2-Thermal_Battery_SOW_LISSE_FINAL_TOC_rev2.docx

High-Temperature Tolerant Batteries (HTTBs) For Long-Life In-situ Solar System Explorer (LLISSE) Statement of Work

Table of Contents

Cell Chemistry and Case Design Testing Option 1: Battery Prototype Integration and Testing

List of Tables

Table of Figures

INTRODUCTION

NASA’s Venus Science Project is developing battery technologies to support the LLISSE Venus surface mission. The goal is to eventually deliver Technology Readiness Level (TRL) 6 hardware for their Preliminary Design Reviews. The technical objective for batteries is to meet the performance requirements of the energy storage system for the High-Temperature Tolerant Batteries (HTTBs) For Long-Lived In-situ Solar System Explorer (LLISSE) Venus surface probe. NASA is developing high temperature rechargeable battery technology to meet Venusian surface probe needs, focusing on improving safety, low self-discharge, high specific energy, and high energy density. This work will culminate in battery-level demonstrations at TRL 6 with candidate designs and performance predictions for battery systems tailored for the LLISSE surface probe.

NASA has a dual-approach for battery development. Figure 1. highlights the first version a) of the LLISSE probe which does not have a wind turbine, and is powered only by the charged battery and operated only in the discharge mode. Surface winds on Venus recharge the battery via a small wind turbine mounted on the top in the second version b) of the LLISSE prototype probe as depicted in Figure 2. It is anticipated that this HTTB development program will yield a high temperature rechargeable battery chemistry that would support both mission scenarios.

The first approach is to develop HTTB technology to achieve safe, long-life high specific energy operation to meet the customer needs as described in the Key Performance Parameters (KPP) in Table 1 of Attachment A. “Pertinent Minimum Performance Requirements”.

Long-duration surface missions on Venus present extreme temperature, pressure, and corrosion challenges. The HTTB battery shall be designed to survive up to 60 Earth days in temperatures ranging from 400°C to 460°C. The HTTB technology becomes an ambient-temperature solution for Venus. The approximate pressure on the surface of Venus is 95 atmospheres. In addition, the various chemical species in the atmosphere include those specified in Table 1 of Attachment A entitled ”Reference Venus Surface Atmosphere for LLISSE”.

The developed components and prototypes performance will be tested under simulated Venus surface conditions including temperature, pressure, and chemical composition of the atmosphere within the Glenn Extreme Environments Rig (GEER) to characterize subsystem level performance. The developmental HTTB units will be tested in the GEER facility to ascertain performance and overall suitability for LLISSE missions. The purpose of this development effort is to foster competition for rechargeable high temperature batteries for future Venus surface missions. Based upon available resources, the intent of this effort is to award multiple development contracts based on the lowest price technically acceptable proposals to assess various battery chemistries for use on LLISSE missions. Based upon initial screening tests on small capacity and low voltage batteries, a down selection process would follow and the Option #1 would be exercised to proceed with a full scale prototype battery procurement for performance characterization to successfully raise the Technology Readiness Level for the HTTB to TRL 6.

NASA’s OBJECTIVE NASA’s overall objective of the work defined in this statement of work is to coordinate the activities associated with the design, development, and fabrication of hardware for an alternative rechargeable high temperature battery development in support of NASA’s Venus Science Mission Programs including LISSE surface probes.

Figure 1. Version a) of the LLISSE probe and is powered only by the charged battery.

Figure 2. Version b) of the LLISSE probe with the wind turbine for recharging the battery.

CONTRACTOR’S PURPOSE

The Contractor shall perform manufacturing evaluations on the NASA selected components to ascertain practical demonstration on aerospace quality electrochemical cell designs for the NASA Glenn Research Center to evaluate various designs to assist in mission enhancing modes for their science applications. In addition, the hardware fabricated under this contract shall undergo performance testing to demonstrate adequate margins under specific mission operating conditions. Finally, in the Optional Phase of the contract, the Contractor will deliver a production lot of batteries for NASA evaluation.

This alternate chemistry approach carries a very high technical risk since these chemistries are at very low TRL. The batteries will be taken from TRL 4 through TRL 6 by performance and environmental testing at NASA. We define TRL 4 to be the integration of the components into a battery, TRL 5 is reached by performance testing to verify battery-level goals, and TRL 6 demonstrates battery-level performance in a relevant thermal, vacuum, vibration, electrical and radiation environment. The schedule listed in Figure 3. highlights the overall approach.

Figure 3. HTTB Master Schedule

SCOPE OF WORK

The Contractor shall furnish personnel, facilities, materials, services, and equipment to accomplish the tasks specified below. The work shall include the design, analysis, evaluation, fabrication, test, instrumentation, and bread boarding of components and batteries.

The key deliverable item to the Government for the basic work portion shall be the design, development, material scale-up, screening, battery fabrication, and delivery of the rechargeable High Temperature Tolerant Battery design chemistry capable of supporting NASA’s Venus surface missions. The battery deliverables for the basic work portion will be of a low voltage < 5 volts and low ampere-hour capacity but similar operational current density for the LLISSE mission using representative manufacturing and assembly techniques. The deliverables for the optional task are the design, development, fabrication, and delivery of the “Prototype” battery configuration and hardware.

To accomplish this work, the Contractor shall perform the specific tasks detailed below. The Contractor shall submit a work plan in accordance with the Reports of Work clause of this contract.

TECHNICAL TASKS

The Contractor shall design HTTBs. The following guideline features shall be incorporated into the battery design:

The design shall be based on the meeting the minimum requirements listed in Attachment A.

APPLICABLE DOCUMENTS

The design of the Venus prototype rechargeable thermal battery is divided into three phases. The first phase focuses on testing of the cell chemistry in Venus surface temperature simultaneously with separate testing of a mock Venus battery case in Venus surface conditions. The mock Venus battery case will be tested at NASA GRC, and can be any standard case the vendor as available with a typical seal. A selection will be made on technical feasibility and the chosen cell chemistry and case will then be integrated for Option 1 testing, and then proceed to Option 2 manufacture and testing. The chosen vendor will be able to design the Venus battery, and manufacture it also because of the possibility of contamination between cell chemistries.

Cell Chemistry and Case Design Testing The initial phase of the Venus battery development will consist of testing of proposed cell chemistry in Venus temperature at the vendors facility prior to integration with a case as described in Option 1. The test plan will be reviewed and approved by NASA prior to testing, and interpreted test data will be provided to NASA according to approved NASA format (similar to Option 1). The test plan will be delivered 10 days prior to the start of testing. The test will last 60 Earth days or until failure.

The proposer will provide an empty stainless steel 92 bar external pressure battery case with six penetration feed throughs on top with recommended seal approaches (i.e.glass to metal, metal crimp seal, ceramic seal, ref. NASA/TM 219437), and those three pairs will be wired internally to connect to monitor voltage continuity over time to validate seal integrity for the Venus atmosphere as described in key performance parameters Appendix A. One case with paired seal approaches will be provided to NASA and tested at a NASA test facility.

Option 1 : Battery Prototype Integration and Testing Baseline HTTB-based design The Contractor shall develop and deliver to NASA a baseline design of a High Temperature Tolerant Battery. The design shall be based upon a mixture of state-of-the-art technology plus advanced components and shall consider the evaluation of battery system level impacts, i.e., watt-hour efficiency, thermal effects, materials compatibility, weight and volume and their effects on total power system mass and volume. The Contractor shall build upon the existing knowledge base and identify any component or design modifications that address performance enhancements for NASA’s LLISSE Program.

Component Design For the purpose of the Baseline battery design, internal stack elements shall be identified using state-of-the-art components. Attributes that shall be considered in the selection of the components include performance, weight, component availability, manufacturability, qualified processes, and cost. Materials compatibility shall also be considered. The Contractor shall support selections and identify advantages, disadvantages, difficulties and limitations associated with the selections. Selection of the baseline candidates shall be in consultation with, and with the approval of, the NASA Project Manager.

The following cell components are required:

a. Cathode

b. Separator

c. Anode

d. Electrolyte Battery Mechanical Design The design of the advanced HTTB shall address the mechanical design of the following structural components:

a. Battery containment

b. Terminals

c. Mechanical support of internals

d. Seals

e. other The Contractor shall identify materials, dimensions, a conceptual design detailing component orientation, and a scheme for battery construction and activation. The Contractor shall support selections and identify advantages, disadvantages, difficulties and limitations involved with the selections. Contractor recommendations regarding the battery mechanical design shall be performed in consultation with, and with the approval of, the NASA Project Manager.

Thermal Design The Contractor shall perform and document thermal analyses and make predictions of thermal gradients for the Baseline battery design to ensure that adequate thermal input is provided to address temperature requirements for optimal operation, given the proposed design of the battery, cell components, and structural elements. Contractor recommendations regarding the thermal design shall be performed in consultation with, and with the approval of, the NASA Project Performance Metrics The Contractor shall evaluate the estimated performance of the candidate components selected for the anticipated cell design to accurately assess the impact to the cell and battery characteristics listed in Table 1.

Commercially Available Sources The Contractor may procure components from commercially available sources and either use them as received or modify the materials to improve their overall performance characteristics to meet or exceed the Key Performance Parameters as outlined in Table 2.

Component Screening Process The Contractor shall complete the component screening process to determine suitability for scale-up described in this task within 1 months after the initiation of the contract.

Cathode Electrode Identification The Contractor shall identify the best electrode candidates. The following parameters shall be identified for the electrodes: electrode substrate, substrate porosity, electrode thickness, active material source, binder and diluent additives and their respective quantities. Selection of the electrode candidates shall be performed in consultation with, and with the approval of, the NASA Project Manager.

Electrode Acceptance Test Plan The Contractor shall deliver their current operational test plan for the evaluation and acceptance of the cathodes. The test plan shall including acceptance/screening tests that include the typical pass/fail measurements. The cathode acceptance test plan shall be approved by the NASA Project Manager.

Manufacturing The Contractor shall provide sufficient rationale regarding the manufacturing and scale-up of the baseline cathode.

Testing/Evaluation The Contractor shall provide sufficient rationale regarding the testing and evaluation of the baseline cathode.

Separator Separator Identification The Contractor shall identify the desired separator properties required for optimal operation of the proposed Baseline HTTB design. The Contractor shall then identify the best separator material, exhibiting those properties, for use in the battery from the sources available and support selection with technical rationale. Selection of the separator properties and candidate separator materials shall be performed in consultation with and with the approval of the NASA Project Manager. The Contractor shall prepare and deliver a report summarizing the desired properties and the survey of candidate separator materials to NASA.

Separator Acceptance Test Plan The Contractor shall deliver their current operational test plan for the evaluation and acceptance the separator. The test plan shall include acceptance/screening tests that include the typical pass/fail criteria. The separator acceptance test plan shall be approved by the NASA Project Manager.

Manufacturing The Contractor shall provide sufficient rationale regarding the manufacturing and scale-up of the baseline separator.

Testing/Evaluation The Contractor shall provide sufficient rationale regarding the testing and evaluation of the baseline separator.

Anode Material Identification The Contractor shall identify the best available material for use in the negative electrode in the Baseline HTTB, from the sources available. The following characteristics shall be identified for the anode: composition, preparation methods, specific capacity (mA-hr/gram), stability, cost, self-discharge characteristics, and availability. Selection of the candidate material shall be performed in consultation with and with the approval of the NASA Project Manager.

Electrode Acceptance Test Plan The Contractor shall provide their current operational test plan for the evaluation and acceptance of the anode electrodes. The test plan shall include acceptance/screening tests that include the typical pass/fail criteria. The anode acceptance test plan shall be approved by the NASA Project Manager.

Manufacturing The Contractor shall provide sufficient rationale regarding the manufacturing and scale-up of the baseline anode.

Testing/Evaluation The Contractor shall provide sufficient rationale regarding the testing and evaluation of the baseline anode.

Electrolyte Electrolyte Identification The Contractor shall identify the desired electrolyte properties required for optimal operation of the proposed Baseline HTTB design. The Contractor shall then identify the best electrolyte(s) exhibiting those properties, for use in the battery from the sources available and support selection with technical rationale. Selection of the electrolyte properties and candidate electrolyte blends shall be performed in consultation with and with the approval of the NASA Project Manager. The Contractor shall prepare and deliver a report summarizing the desired properties and the survey of candidate separator materials to NASA.

Electrolyte Acceptance Test Plan The Contractor shall provide their current operational test plan for the evaluation and acceptance of the electrolyte. The test plan shall include acceptance/screening tests that include the typical pass/fail criteria. The electrolyte acceptance test plan shall be approved by the NASA Project Manager.

Manufacturing The Contractor shall provide sufficient rationale regarding the manufacturing and scale-up of the baseline electrolyte.

Testing/Evaluation The Contractor shall provide sufficient rationale regarding the testing and evaluation of the baseline electrolyte.

Screening “Baseline” HTTB Screening Battery Design The Contractor shall utilize the results of Tasks AA-BD and conduct other research to identify system hardware, materials, and components which offer the best features for the preliminary design of the “Baseline” HTTBs cell chemistry incorporating the features and characteristics described in requirements defined in Section 5.0 Technical Tasks, features a. – f. and minimum requirements in Appendix A. The preliminary battery design shall be a refinement of the baseline design defined in Task A. For the purposes of defining the preliminary design, the Contractor shall incorporate recommendations, and component selections from the evaluations performed in Tasks B. The design shall consider the evaluation of cell and battery system level impacts, i.e., watt-hour efficiency, thermal effects, materials compatibility, weight and volume and their effects on total energy storage system mass and volume. The Contractor shall specify the type of battery screening format to be utilized for the purpose of screening the various components or other production level battery configuration.

Preliminary Design Review Preliminary Design Review The Preliminary Design Review (PDR) shall be held via Webex/Telecon between NASA and the Contractor within 1 months after award of the contract.

Preliminary Design Review Data Package The Preliminary Design Review data package shall contain projected performance characteristics, design limitations, test plans, pertinent test results and descriptions, parts, materials and processes lists, mass properties list, and manufacturing schedule. The Contractor shall electronically submit copies of the Preliminary Design Review data package covering the information to be addressed at the PDR to NASA at least two weeks prior to the design review with sufficient narrative to demonstrate adequacy of the “Baseline” screening battery designs.

Preliminary Design Review Design, Specifications, and Processes The Contractor shall electronically submit complete copies of the designs and specifications involved with the construction of the “Baseline” screening batteries to NASA for review and approval. If the designs, specifications, or plans are disapproved, the NASA Project Manager will indicate specifically what changes are necessary to obtain approval and the Contractor shall execute the necessary changes. The Contractor shall not proceed with further work on Task C until the design is approved with the exception of the long lead items already approved. Pre-approved items may be subject to modifications based on additional review.

Preliminary Design Review Summary Report The Contractor shall provide a summary report on the Preliminary Design Review containing at least the meeting minutes and roster of attendees, information and agreement items, identification and assignment to a responsible individual of each action item with a due date. The summary report shall be delivered to NASA within two weeks after conducting the design review.

Fabrication of Screening Batteries After receiving approval on the Preliminary Design Review from the NASA Project Manager, the Contractor shall commence fabrication of the “Baseline” Battery. The Contractor shall deliver five (5) batteries that will be of a low voltage < 5 volts and low ampere-hour capacity but similar operational current density for the LLISSE mission using representative manufacturing and assembly techniques subject to the review and approval of the NASA Project Manager.

Long lead item component drawings may be submitted to NASA for approval prior to the Preliminary Design Review, so that component manufacturing can begin in order to meet fabrication schedules.

Testing of Preliminary Batteries The Contractor shall test each of the Screening batteries fabricated in Task CD following completion of their manufacture. The Contractor shall submit test plans for the testing to NASA 10 days prior to testing. The test plans are subject to the review and approval of the NASA Project Manager.

As a minimum, the following data shall be monitored and recorded for each test of the “Baseline” HTTBs:

a. battery voltages

b. battery temperatures

c. charge/discharge current

d. time

e. charge ampere-hours

f. discharge ampere-hours

g. watt-hours on charge

h. watt-hours on discharge

i. cycle number

j. test conditions Capacity Determination Capacity shall be measured at 450oC and 400oC. Three measurements at each shall be made. The average of the 450oC measurements shall be defined as the capacity, C for the battery. The Capacity Determination Plan shall be determined in consultation with, and with the approval of the NASA Project Manager. Upon approval of the Capacity Determination Plan, the Contractor shall commence capacity testing.

Charge Retention Measurement Open circuit voltage decay shall be determined for 288 hours at 450oC at 100% state-of-charge. Voltage measurements to the millivolt level shall be taken at 6 hour periods or less during the open circuit period. Following the 288 hour open circuit stand, the batteries shall be discharged under the baseline power profile. The Battery Charge Retention Plan shall be determined in consultation with, and with the approval of the NASA Project Manager. Upon approval of the Battery Charge Retention Plan, the Contractor shall commence charge retention testing.

Test Report The Contractor shall submit a report for review and NASA approval covering the results pertaining to capacity determination testing, charge retention testing, and the Contractor’s standard acceptance testing to determine suitable temperature and ampere-hour capacity performance.

Characterization Tests The Buyer will conduct characterization tests at 400oC, 425oC, and 450oC, with charge and discharge rates as follows:

C = Average of the three 450oC capacity determination cycles performed in CEA.

The cut-off voltage on discharge shall be when the battery reaches 0.75 volts (TBR). Duplicate tests shall be conducted for each set of conditions. After each charge-discharge cycle, the battery will be discharged to 0.75 volts (TBR) before initiation of the subsequent cycle.

Functional Cycling Test The Buyer will perform functional testing on each battery under a simulated mission profile mode. The battery will be cycled under the load profile contained in Attachment A.

Recommendations and Final Design Upon completion of the testing required by Task C and review of the characterization and functional testing, the Contractor shall generate a list of recommended changes to the preliminary design which were identified upon evaluation of the test results performed as part of Task C. The Contractor shall submit a report to NASA that recommends specific design improvements that enhance the electrical performance, ease of manufacture of the design, or manufacturing processes.

The Contractor shall incorporate NASA-approved changes into the Final design documentation. The Contractor shall submit two copies of the Final Design document, to NASA.

baseline DELIVERABLES

· The contractor shall deliver a mock battery case for testing in the Glenn Extreme Environment Rig (GEER) while testing a proposed cell chemistry. This cell chemistry test will be completed 90 to 120 days after contract award. The battery case will be delivered 60 days after contract award. If the cell chemistry test is successful, the battery will be integrated with a viable case and Task A will begin.

· The contractor shall work in consultation with the NASA Project Manager to develop and deliver to NASA a baseline design for a High Temperature Tolerant Battery as detailed in Task A.

· The component screening process shall be performed as described in Task B.

· The contractor shall deliver their current operational test plan to the NASA Project Manager for the evaluation and acceptance of the cathodes, separators, anodes, and electrolytes for approval.

· The contractor shall use Task A and Task B results to create a preliminary battery design as described in Task C.

· The Contractor shall electronically submit copies of the Preliminary Design Review data package covering the information to be addressed at the PDR to NASA at least two weeks prior to the design review with sufficient narrative to demonstrate adequacy of the “Baseline” screening battery designs.

· The Contractor shall electronically submit complete copies of the designs and specifications involved with the construction of the “Baseline” screening batteries to NASA for review and approval.

· The Contractor shall provide a summary report on the Preliminary Design Review containing at least the meeting minutes and roster of attendees, information and agreement items, identification and assignment to a responsible individual of each action item with a due date.

· The contractor shall commence fabrication of the “Baseline” Battery after receiving approval on the Preliminary Design Review from the NASA Project Manager.

· Long lead item component drawings may be submitted to NASA for approval prior to the Preliminary Design Review, so that component manufacturing can begin in order to meet fabrication schedules.

· The contractor shall submit test plans for the testing of the “Baseline” Battery as described in Task CE.

· The Contractor shall submit a report for review and NASA approval covering the results pertaining to capacity determination testing, charge retention testing, and the Contractor’s standard acceptance testing as described in Task CEC.

· The Contractor shall submit a report to NASA that recommends specific design improvements after the completion and acceptance of the testing in Task C.

All reports will be provided with unlimited data rights. An MSDS sheet will be provided to the NASA project manager for each electrolyte and/or material used for the fabrication of the battery prototype. The explosive potential (TNT equivalent) will be documented for each prototype along with overall size.

Pertinent Minimum Performance Requirements

Maximum Outline Dimensions = 17 cm X 17 cm X 7 cm

Maximum Allowable Mass = 2.86 kg

Minimum Battery Level Specific Energy = 28.6 Wh/kg

Operating Voltage = +25V +0/-6 volts and -25V +6/-0 volts

Self-Discharge Rate = maximum self-discharge less than 3%/month at +4600C (TBR)

Non-operating Environment

Long Term Storage at Room Temperature and 1 atmosphere

-930C during transit to Venus under hard space vacuum

Operating Environment

Table 3. Reference Venus Surface Atmosphere for LLISSE

Mole Fraction

Percent Conc.

Electrical Power Demand The anticipated power draw from the LLISSE battery supports two major loads. One is a continuous load of 0.01 Watts for a timer circuit that provides a clock sequencer for communication. During the 60 Earth day mission, it consumes 14.4 Watt-hours. The second load addresses the periodic communication link transmitting data on the scientific instruments and sensors. Here, the load consists of a 10 Watt load for two minutes in duration which occurs every 8 hours. During the 60 Earth day mission, it consumes 60.0 Watt-hours. Therefore, the total energy demand from the energy storage system is 74.4 Watt-hours.

Design Life The battery shall be designed for a minimum operational design life of 2.5 Earth months (under the discharge-only mode of operation), when operated at the power levels described above in Table 1 at the temperature specified therein, and after storage.

Storage Life The battery shall be capable of meeting the requirements of this specification after a storage period of up to 4 years at room temperature and 1 atmosphere pressure after the battery final manufacturing date.

Limited Life Items Limited life and/or age-sensitive parts shall be identified, including criteria for age sensitivity, manufacture date, activation date, restoration, and life extension.

Option 2: Manufacturing “Prototype” Production Lot of Batteries The following task, Task 1, is optional at the unilateral discretion of the Government and shall have as its primary purpose the fabrication/production of large ampere-hour capacity “Prototype” HTTBs to meet the +25 volt, zero voltage tap, and –25 volt prototype battery design to meet the LLISSE energy storage requirements. The purpose of this Option #1 is to demonstrate synthesis and fabrication capability along with scale-up to the anticipated proper energy storage voltage, ampere-hour capacity, and performance characteristics for LLISSE.

Prototype HTTB Critical Design Review The Contractor shall hold the Critical Design Review via Webex/telecon with NASA Glenn Research Center within 30 days after award of Optional Task 1.

Critical Design Review Data Package The Critical Design Review data package shall contain performance characteristics, design limitations, test plans, pertinent test results and descriptions, parts, materials and processes lists, mass properties list, and manufacturing schedule. The Contractor shall submit the complete Critical Design Review data package electronically covering the information to NASA at least two weeks prior to the design review with sufficient narrative to demonstrate adequacy of the “Prototype” battery design.

Final Design, Drawings, Specifications, and Processes The Contractor shall electronically submit complete copies of the designs and specifications involved with the construction of the “Prototype” HTTBs to NASA for review and approval. If the designs, specifications, or plans are disapproved, the NASA Project Manager will indicate specifically what changes are necessary to obtain approval and the Contractor shall execute the necessary changes. The Contractor shall not proceed with further work on Task 1 until the design is approved with the exception of the long lead items already approved. Pre-approved items may be subject to modifications based on additional review.

Critical Design Review Summary Report The Contractor shall provide a Final Critical Design Review Summary Report containing at least the meeting minutes and roster of attendees, information and agreement items, identification and assignment to a responsible individual of each action item with a due date. The summary report shall be delivered to NASA within two weeks after conducting the design review.

Fabrication of Batteries After successfully completing Task 1D and with approval from the NASA Contracting Officer, the Contractor shall proceed with fabricating batteries to the NASA approved drawings, procedures, and methods specified under Task 1C. The quantity of batteries to be fabricated and delivered to NASA can vary between a minimum of five (5) and a maximum of ten (10) units.

Testing of “Prototype” HTTBs The Contractor shall test each of the “Prototype” batteries fabricated in Optional Task 1 following completion of their assembly. The Contractor shall submit test plans for the testing to NASA 30 days prior to assembly. The test plans are subject to the review and approval of the NASA Project Manager.

As a minimum, the following data shall be monitored and recorded for each test of the “Prototype” HTTBs:

a. battery voltages

b. battery temperatures

c. charge/discharge current

d. time

e. charge ampere-hours

f. discharge ampere-hours

g. watt-hours on charge

h. watt-hours on discharge

i. cycle number

j. test conditions Capacity Determination Capacity shall be measured at 400oC and 450oC after stabilizing the internal temperature. Three measurements shall be made. The average of the 450oC measurements shall be defined as the capacity, C for the battery. The Capacity Determination Plan shall be determined in consultation with, and with the approval of the NASA Project Manager. Upon approval of the Capacity Determination Plan, the Contractor shall commence capacity testing.

Charge Retention Measurement Open circuit voltage decay shall be determined for 288 hours at 450oC at 100% state-of-charge. Voltage measurements to the millivolt level shall be taken at 6 hour periods or less during the open circuit period. Following the 288 hour open circuit stand, the battery shall be discharged at a C/20 rate (TBR). The Battery Charge Retention Plan shall be determined in consultation with, and with the approval of the NASA Project Manager. Upon approval of the Battery Charge Retention Plan, the Contractor shall commence charge retention testing.

Test Report The Contractor shall submit a report for review and NASA approval covering the results pertaining to capacity determination testing, charge retention testing, and the Contractor’s standard acceptance testing to determine suitable temperature and ampere-hour capacity performance.

Delivery of Hardware Upon completion of the Contractor’s acceptance and qualification testing of the batteries, the NASA Project Manager shall direct the shipment of the hardware to NASA Glenn Research for further testing/integration with the missions.

Data Package Delivery The Contractor shall maintain a log documenting the actual procedures and details of the battery construction and activation. Information relating to the component and electrolyte weights, temperatures, pressures, charge and discharge rates and times, and battery voltages shall be included in the log. An electronic copy of the log shall be delivered to NASA with the batteries.

Acceptance Testing Requirements The batteries shall be fabricated to meet the SMC-S-016 “Test Requirements for Launch, Upper Stage, and Space Vehicles” and the LeR-M0510.002 “Standard Assurance Requirements and Guidelines for Experiments” incorporated herein by reference. Acceptance level testing shall include as a minimum functional tests, shock, acoustic, random vibration, thermal vacuum, thermal cycle, proof pressure, and leakage tests. All batteries will undergo acceptance level testing. The Buyer will conduct the Acceptance testing.

Qualification Testing Requirements The batteries shall be fabricated to meet the SMC-S-016 “Test Requirements for Launch, Upper Stage, and Space Vehicles” and the LeR-M0510.002 “Standard Assurance Requirements and Guidelines for Experiments”. Qualification level testing shall include as a minimum functional tests, shock, acoustic, random vibration, thermal vacuum, thermal cycle, proof pressure, and leakage tests. At least 3 batteries shall undergo qualification level testing and pass the required minimum performance criteria. The Buyer will conduct the qualification testing.

Option DELIVERABLES

· The contractor shall complete Critical Design Review as described in 1A and 1B, and submit the Critical Design Review data package as described in 1B.

· The contractor shall obtain design approval as detailed in 1C.

· The contractor shall submit a Critical Design Review Summary Report as described in 1D.

· The contractor shall fabricate prototype batteries as described in 1E, and deliver a minimum of five (5) and a maximum of ten (10) unites to NASA.

· The contractor shall submit test plans for the battery “prototype” as described in 1F.

· A Capacity Determination Plan shall be submitted as described in 1G.

· A Battery Charge Retention Plan shall be developed as described in 1H.

· An overall Test Report shall be submitted to NASA for review as described in 1I.

· The contractor shall ship the hardware to NASA as described in 1J.

· An electronic copy of the battery construction and activation log described in 1K shall be delivered to NASA with the batteries.

All reports will be provided with unlimited data rights. An MSDS sheet will be provided to the NASA project manager for each electrolyte and/or material used for the fabrication of the battery prototype. The explosive potential (TNT equivalent) will be documented for each prototype along with overall size.

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