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Nb3Sn has the potential to achieve superior performance in terms of quality factor, accelerating gradient and operating temperature (4.2 K vs 2 K) resulting in significant reduction in both capital and operating costs compared to traditional niobium SRF accelerator cavities. Tin vapor diffusion coating of Nb3Sn on niobium appears to be a simple, yet most efficient technique so far to fabricate such cavities. Here, cavity interior surface coatings are obtained by a two step process: "nucleation" followed by "deposition". The first step is normally accomplished with Sn/SnCl2 at a constant low temperature (~500 °C) for several hours. To elucidate the role of this step, we systematically studied the niobium surface nucleated under varying process conditions. The surfaces obtained in typical tin/tin chloride processes were characterized using SEM/EDS, AFM, XPS, SAM and TEM. Examination of the surfaces nucleated under the "standard" conditions revealed not only tin particles, but also tin film on the surfaces resembling the surface obtained by Stranski-Krastanov growth mode. All the nucleation attempted with SnCl2 yielded better uniformity of Nb3Sn coating compared to coating obtained without nucleation, which often included random patchy regions with irregular grain structure. Even though the variation of nucleation parameters was able to produce different surfaces following nucleation, no evidence was found for any significant impact on the final coating. 6

Superconducting radio frequency niobium cavities are the building blocks of modern accelerators for scientific applications. Lower surface resistance, higher fields, and high operating temperatures advance the reach of the future accelerators for scientific discovery as well as potentially enabling cost-effective industrial solutions. We describe the design and performance of an Nb3Sn coating system that converts the inner surface of niobium cavities to an Nb3Sn film. The niobium surface, heated by radiation from the niobium retort, is exposed to Sn and SnCl2 vapor during the heat cycle, which results in about 2 μm Nb3Sn film on the niobium surface. Film composition and structure as well as radio frequency properties with 1-cell R&D cavities and 5-cell practical accelerator cavities are presented.

Nb3Sn (Tc ≈ 18 K and Hsh ≈ 400 mT) is a prospective material to replace Nb (Tc ≈ 9 K and Hsh ≈ 200 mT) in SRF accelerator cavities for significant cost reduction and performance enhancement. Because of its material properties, Nb3Sn is best employed as a thin film (coating) inside an already built RF cavity structure. A particular test cavity noted as C3C4 was a 1.5 GHz single-cell Nb cavity, coated with Nb3Sn using Sn vapor diffusion process at Jefferson Lab. Cold measurements of the coated cavity indicated the superconducting transition temperature of about 18 K. Subsequent RF measurements indicated fielddependent surface resistance both at 4.3 K and 2.0 K. After initial cold measurements, the cavity RF loss distribution was studied with a thermometry mapping system. Loss regions were identified with thermometry and were cut out for material analysis. The presence of significantly thin patchy regions and other carbonrich defects is associated with strong local field-dependent surface resistance. This paper summarizes RF and thermometry results correlated with material science findings.

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