Abstract-A broad range of coupon electropolishing experiments are described to ascertain the mechanism(s) by which large defects are formed near superconducting radiofrequency (SRF) cavity welds. Cold-worked vs. annealed metal, the presence of a weld, and several variations of electropolishing (EP) parameters were considered. Pitting is strongly promoted by cold work and agitation of the EP solution. Welding also promotes pitting, but less so compared with the other factors above. Temperature increase during EP did not strongly affect glossiness or pitting, but the reduced viscosity made the electrolyte more susceptible to agitation. The experiments suggest that several factors that are rather benign alone are combined by the cavity forming, welding, and processing sequence to promote the formation of defects such as pits. Process changes to mitigate these risks are discussed.

Abstract. Recent coordination of thermometry with optical images has shown that obvious defects at specific locations produce heat or even quench superconducting radio frequency (SRF) cavities, imposing a significant limit on the overall accelerating gradient produced by the cavity. Characterization of the topography at such locations provides clues about how the defects originated, from which schemes for their prevention might be devised. Topographic analyses also provide understanding of the electromagnetic mechanism by which defects limit cavity performance, from which viability of repair techniques might be assessed. In this article we discuss how a variety of two-component siliconebased room-temperature vulcanizing agents can be routinely used to make replicas of the cavity surface and extract topographic details of cavity defects. Previously, this level of detail could only be obtained by cutting suspect regions from the cavity, thus destroying the cavity. We show 3-D profiles extracted from several different 1.3 GHz cavities. The defect locations, which were all near cavity welds, compelled us to develop extraction techniques for both equator and iris welds as well as from deep inside long 9-cell cavities. Profilometry scans of the replicas yield micrometer-scale information, and we describe various curious features, such as small peaks at the bottom of pits, which were not apparent in previous optical inspections. We also discuss contour information in terms of electromagnetic mechanisms proposed by others for local cavity heating. We show that production of the replica followed by high-pressure rinsing dose not adversely affect the cavity RF performance.

Mechanical tests of cavity-grade niobium samples were conducted to provide engineering information for the certification of 3rd-harmonic superconducting radio-frequency cavities and cryomodules. Large changes of mechanical properties occur throughout the cavity fabrication process due to the cold work introduced by forming, the heating introduced by electron beam welding, and the recovery of cold work during the anneal used to degas hydrogen after chemical processing. Data is provided here to show the different properties at various stages of fabrication, including both weld regions and samples from the bulk niobium far away from the weld. Measurements of RRR were used to assure that any contamination during annealing was negligible.

In this study we will show a new method of polishing for Nb3Sn cavities known as centrifugal barrel polishing (CBP). Using this method, Nb3Sn coated samples are polished to a surface roughness comparable to a traditional Nb cavity after electropolishing (EP). We also investigate different methods of cleaning the Nb3Sn surface after CBP to remove residual abrasive particles. The polished Nb3Sn surface is analyzed using confocal laser microscopy, and scanning electron microscopy (SEM) is used to image the surface and measure the surface roughness after polishing. Transmission electron microscopy (TEM) is also used for high resolution analysis of the surface after polishing. Finally, we show that centrifugal barrel polishing can improve the performance of a Nb3Sn SRF cavity.