Superconducting radiofrequency (SRF) cavities that could provide a higher quality factor as well as a higher operational accelerating gradient at an affordable cost are in high demand for the future generation of particle accelerators. This study aims to demonstrate the potential of Nb3Sn as material of choice for such SRF applications. Due to its brittle nature, the only way to produce an Nb3Sn SFR cavity is to synthesise a thin layer inside a cavity made of niobium or copper. In this work, direct current magnetron sputtering using a stoichiometric target of Nb3Sn was employed to produce films on copper samples. Assessment of the morphology, microstructure and superconducting properties were performed in order to ensure that this approach is suitable for SRF applications. The potential of the method is proven by obtaining films, which exhibit a crack-free surface, dense morphology and critical temperatures (Tc) up to 16 K. The essential properties of the films have also been investigated with respect to the deposition and annealing conditions. The use of krypton as working gas during deposition increases the atomic percent of Sn in the film compared to argon. However, in contrast to argon, higher krypton pressures reduce the atomic percent of Sn. It was also found that long-lasting high-temperature annealing leads to higher superconducting critical temperatures due to an increased crystallographic order. Particular attention was given to the influence of the copper substrate on the film growth as well as the microstructural and superconducting characteristics. We discuss the main constraints introduced by the copper substrate, such as copper interdiffusion during annealing, lattice mismatch and difference in thermal expansion coefficients and methods to overcome them.

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Superconducting rf (SRF) cavities are traditionally fabricated from superconducting material sheets or made of copper coated with superconducting material, followed by trim machining and electron-beam welding. An alternative technique to traditional shaping methods, such as deep-drawing and spinning, is electrohydraulic forming (EHF). In EHF, half-cells are obtained through ultrahigh-speed deformation of blank sheets, using shockwaves induced in water by a pulsed electrical discharge. With respect to traditional methods, such a highly dynamic process can yield interesting results in terms of effectiveness, repeatability, final shape precision, higher formability, and reduced springback. In this paper, the first results of EHF on high purity niobium are presented and discussed. The simulations performed in order to master the multiphysics phenomena of EHF and to adjust its process parameters are presented. The microstructures of niobium halfcells produced by EHF and by spinning have been compared in terms of damage created in the material during the forming operation. The damage was assessed through hardness measurements, residual resistivity ratio (RRR) measurements, and electron backscattered diffraction analyses. It was found that EHF does not worsen the damage of the material during forming and instead, some areas of the half-cell have shown lower damage compared to spinning. Moreover, EHF is particularly advantageous to reduce the forming time, preserve roughness, and to meet the final required shape accuracy.

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