Engineering topics

Posen, S. [Fermilab]

Publications and source records attributed to Posen, S. [Fermilab].

6 records

DOE OSTI2026

Development of in situ thickness sensor for vapor diffused Nb3Sn films

Fermilab is one of the leaders in development of vapor diffused Nb3Sn films inside niobium cavities. This material has a higher critical temperature (Tc) than niobium, enabling cavity operation at 4.2 K. This higher operational temperature significantly reduces the infrastructure required for cooling compared to 2 K systems, making superconducting radio-frequency (SRF) technology more accessible. Current deposition methods have relied on iterative testing to determine nominal film thickness, a process that can be time-consuming and imprecise. To address this, we are developing a sensor to measure the thickness of Nb3Sn thin film in situ during vapor diffusion. Our design involves the resistance measurement of a thin film of niobium. During coating, the change in resistance reflects the conversion of the film to Nb3Sn, which allows simple integration with the current furnace infrastructure. This sensor would allow real time measurement of the thickness, allowing for increased precision in future depositions.

Howard, K. [Unlisted] (ORCID:0000000325613308)↗

DOE OSTI2026

Development of in situ thickness sensor for vapor diffused Nb3Sn films

Fermilab is one of the leaders in development of vapor diffused Nb3Sn films inside niobium cavities. This material has a higher critical temperature (Tc) than niobium, enabling cavity operation at 4.2 K. This higher operational temperature significantly reduces the infrastructure required for cooling compared to 2 K systems, making superconducting radio-frequency (SRF) technology more accessible. Current deposition methods have relied on iterative testing to determine nominal film thickness, a process that can be time-consuming and imprecise. To address this, we are developing a sensor to measure the thickness of Nb3Sn thin film in situ during vapor diffusion. Our design involves a four-point resistance measurement of a thin film of niobium, inside the coating region. During coating, the change in resistance reflects the conversion of the film from Nb to Nb3Sn, which allows simple integration with the current furnace infrastructure. This sensor would allow real time measurement of the Nb3Sn film thickness, allowing for increased precision in future depositions for cavity applications.

Howard, K. [Chicago U.] (ORCID:0000000325613308)↗

DOE OSTI2026

Mechanically Polishing Electroplated Nb3Sn for Higher Accelerating Gradients

As the demand for more efficient SRF technology continues to rise, so does the need to improve the performance of Nb3Sn, the most promising alternative to niobium. Leveraging recent breakthroughs in Nb3Sn research from Cornell University and Fermilab, namely the electrochemical synthesis-based growth of Nb3Sn and the centrifugal barrel polishing (CBP) technique to smoothen the final Nb3Sn film, our primary goal is to reduce surface roughness while preserving the film’s quality. We present promising RF results from an electroplated cavity that underwent mechanical polishing using the CBP technique, which showed an increase in the maximum accelerating gradient compared to the baseline test. However, contamination-induced Q-slope limited performance. Temperature mapping reveals quench location and heating response before, during and after quench.

Shpani, L. [Cornell U.]↗

DOE OSTI2026

Broad frequency tuning of a Nb$_{3}$Sn superconducting microwave cavity for dark matter searches

We demonstrate a novel broad-frequency tuning mechanism for superconducting microwave cavities designed for dark matter searches. Using a Nb$_3$Sn-coated cigar-shaped cavity operating at approximately 9 GHz, we achieve continuous frequency tuning exceeding 1 GHz by mechanically separating the two cavity halves: a "tuning-by-opening" technique. Finite-element method simulations predict that radiative losses do not degrade the quality factor even for large openings, as a closed cavity with an intrinsic quality factor of $10^7$ maintains this value for apertures up to 9 mm, corresponding to a tuning range from 9.0 to 7.5 GHz. Experimental validation using both copper ring spacers and a continuous sliding mechanism confirms $Q_0$ values exceeding the dark matter quality factor across the entire explored frequency range, despite mechanical imperfections and film non-uniformities. This tuning approach avoids inserting elements into the resonant volume, making it particularly suitable for high-Q superconducting cavities in axion haloscope experiments and readily applicable to REBCO-based implementations capable of operating in multi-tesla magnetic fields.

Maiello, D. [Padua U.; INFN, Padua] (ORCID:0009000↗

DOE OSTI2026

Nb3Sn Superconducting Cavity Developments for Heavy-ion Beams

Nb3Sn has been identified as the most promising next-generation superconducting material for accelerator cavities. This is due to the higher critical temperature (Tc = 18 K) of Nb3Sn compared to niobium (Tc = 9.2 K), which leads to greatly reduced RF losses in the cavity during 4.5 K operation. This allows two important changes during cavity and cryomodule design. First, the higher Tc leads to negligible BCS losses when operated at 4.5 K, which allows for a higher frequency to be used, translating to significantly smaller cavities and cryomodules. Second, the reduced dissipated power lowers the required cryogenic cooling capacity, meaning that cavities can feasibly be operated on 5-10 W cryocoolers instead of a centralized helium refrigeration plant. These plants and distribution systems are costly and complex, requiring skilled technicians for operation and maintenance. These fundamental changes present an opportunity for a paradigm shift in how low-beta linacs are designed and operated. Fabrication and testing results of first prototypes are discussed.

Petersen, T. [Argonne]↗

DOE OSTI2025

Studies as a function of different ALD capping layers on cavity losses for QIS and accelerators

Niobium-based bulk SRF cavities have demonstrated exceptional performance. To further improve niobium cavity performance, we present studies involving a novel surface engineering process designed to prevent the formation of amorphous niobium oxides on the surface. This is achieved by encapsulating the niobium surface using thermal Atomic-Layer-Deposition (ALD). This technique has been shown to enhance the properties of niobium cavities and 2D resonators. This study not only aims to improve SRF performance at high fields but also has the potential to enhance the quality factor in low-field regimes, particularly for quantum applications. For the method to be effective, it is essential to have a clean interface between the encapsulating layer and the bulk niobium. Achieving this requires a uniform coating across the entire cavity surface and efficient removal of the underlying niobium oxides. To optimize the process, a variety of material characterization tools have been utilized to refine parameters such as thin film thickness and annealing conditions. Cavity RF measurements were performed at the vertical test facilities at FNAL to assess the Q vs. Eacc curves for accelerator applications, as well as at the SQMS dilution refrigerators to investigate the full two-level system (TLS) losses at milliKelvin and single-photon levels. Based on the results, we characterized the loss of different oxides in various regimes and applications, comparing them to natural niobium pentoxide.

Grassellino, L. [Fermilab]↗