Nb3Sn is a promising next-generation material for superconducting radiofrequency cavities, with significant potential for both large scale and compact accelerator applications. However, so far, Nb3Sn cavities have been limited to continuous wave accelerating fields <18 MV m−1. In this paper, new results are presented with significantly higher fields, as high as 24 MV m−1 in single cell cavities. Results are also presented from the first ever Nb3Sn-coated 1.3 GHz 9-cell cavity, a full-scale demonstration on the cavity type used in production for the European XFEL and LCLS-II. Results are presented together with heat dissipation curves to emphasize the potential for industrial accelerator applications using cryocooler-based cooling systems. The cavities studied have an atypical shiny visual appearance, and microscopy studies of witness samples reveal significantly reduced surface roughness and smaller film thickness compared to typical Nb3Sn films for superconducting cavities. Possible mechanisms for increased maximum field are discussed as well as implications for physics of RF superconductivity in the low coherence length regime. Outlook for continued development is presented.

Nb3Sn is a promising advanced material under development for superconducting radiofrequency (SRF) cavities. Past efforts have been focused primarily on small development-scale cavities, but large, often multi-celled cavities, are needed for particle accelerator applications. In this work, we report on successful Nb3Sn coatings on Nb in a 1 m-long 9-cell Nb sample-host cavity at Fermilab. The geometry of the first coating with only one Sn source made it possible to study the influence of Sn flux on the microstructure. Based on these results, we postulate a connection between recently observed anomalously large thin grains and uncovered niobium spots observed in the past by other authors [Trenikhina 2018]. A phenomenological model to explain how these anomalously large grains could form is proposed. This model is invoked to provide possible explanations for literature results from several groups and to guide key process parameters to achieve uniform vapor-diffusion coatings, when applied to complex structures as the multi-cell cavity under study. Using the current methods that achieve strong performance on single-cell cavities and scaling them up to multicell cavities is not necessarily straightforward due to the nature of the process, which involves thermal evaporation of Sn vapor from a heated source. Due to the complex geometry of SRF cavities, substrate surfaces occupy a variety of angles and distances from the source, as well as areas outside of the line-of-sight, issues which have complicated other coating processes as well (e.g. Nb/Cu).

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