The conceptional design of the proposed linear electron-positron collider TESLA is based on 9-cell 1.3 GHz superconducting niobium cavities with an accelerating gradient of E acc $ 25 MV͞m at a quality factor Q 0 $ 5 3 10 9 . The design goal for the cavities of the TESLA Test Facility (TTF) linac was set to the more moderate value of E acc $ 15 MV͞m. In a first series of 27 industrially produced TTF cavities the average gradient at Q 0 5 3 10 9 was measured to be 20.1 6 6.2 MV͞m, excluding a few cavities suffering from serious fabrication or material defects. In the second production of 24 TTF cavities, additional quality control measures were introduced, in particular, an eddy-current scan to eliminate niobium sheets with foreign material inclusions and stringent prescriptions for carrying out the electronbeam welds. The average gradient of these cavities at Q 0 5 3 10 9 amounts to 25.0 6 3.2 MV͞m with the exception of one cavity suffering from a weld defect. Hence only a moderate improvement in production and preparation techniques will be needed to meet the ambitious TESLA goal with an adequate safety margin. In this paper we present a detailed description of the design, fabrication, and preparation of the TESLA Test Facility cavities and their associated components and report on cavity performance in test cryostats and with electron beam in the TTF linac. The ongoing research and development towards higher gradients is briefly addressed.
The production of over 800 1.3-GHz superconducting (SC) cavities for the European X-ray Free Electron Laser (EXFEL), the largest in the history of cavity fabrication, has now been successfully completed. In the past, manufacturing of SC resonators was only partly industrialized; the main challenge for the EXFEL production was transferring the high-performance surface treatment to industry. The production was shared by the two companies RI Research Instruments GmbH (RI) and Ettore Zanon S.p.A. (EZ) on the principle of "build to print". DESY provided the high-purity niobium and NbTi for the resonators. Conformity with the European Pressure Equipment Directive (PED) was developed together with the contracted notified body TUEV NORD. New or upgraded infrastructure has been established at both companies. Series production and delivery of fully-equipped cavities ready for cold rf testing was started in December 2012, and finished in December 2015. More than half the cavities delivered to DESY as specified (referred to "as received") fulfilled the EXFEL specification. Further improvement of low-performing cavities was achieved by supplementary surface treatment at DESY or at the companies. The final achieved average gradient exceeded the EXFEL specification by approximately 25%. In the following paper, experience with the 1.3-GHz cavity production for EXFEL is reported and the main lessons learned are discussed.
DESY activities on 1.3 GHz tesla shape single cell and nine-cell large grain (LG) resonators are presented; results of the past five years are covered. The R&D program explores the potential for production of elliptical superconducting cavities. The main efforts have been devoted to material investigation, development of LG disk production, cavity fabrication from this material, and a search for appropriate treatment. More than 250 LG disks are manufactured; several single cell and 11 nine-cell resonators are produced and rf tested after buffered chemical polishing and after additional electropolishing. A maximum accelerating gradient of approximately 45 MV=m for this type of cavity was achieved in two resonators. Two of the LG cavities have been installed and are currently being used in the FLASH accelerator operation. Assembly of a cryomodule, consisting of LG cavities only, is in the works. Perspectives of the LG cavity application are discussed.
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