Superconducting radio-frequency cavities are commonly used in modern particle accelerators for applied and fundamental research. Such cavities are typically made of high-purity, bulk Nb and are cooled by a liquid helium bath at a temperature of ∼ 2 K. The size, cost and complexity of operating a particle accelerator with a liquid helium refrigerator makes the current cavity technology not favorable for use in industrial-type accelerators. We developed a multi-metallic 1.495 GHz elliptical cavity conductively cooled by a cryocooler. The cavity has a ∼ 2 µm thick layer of Nb3Sn on the inner surface, exposed to the rf field, deposited on a ∼ 3 mm thick bulk Nb shell and a bulk Cu shell, of thickness 5 mm deposited on the outer surface by electroplating. A bolt-on Cu plate 1.27 cm thick was used to thermally connect the cavity equator to the second stage of a Gifford-McMahon cryocooler with a nominal capacity of 2 W at 4.2 K. The cavity was tested initially in liquid helium at 4.3 K and reached a peak surface magnetic field of ∼ 36 mT with a quality factor of 2 × 10 9 . The cavity cooled by the crycooler achieved a peak surface magnetic field of ∼ 29 mT, equivalent to an accelerating gradient of 6.5 MV/m, and it was able to operate in continuous-wave with as high as 5 W dissipation in the cavity for 1 h without any thermal breakdown. This result represents a paradigm shift in the technology of superconducting accelerator cavities.
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.
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