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DOE OSTI2026

Manufacturing Full-Scale High Gradient Copper Accelerators: Electron Beam Welding and Allied Processes

This DOE ARDAP-funded study examines the technical and business feasibility of manufacturing high-gradient normal conducting RF (NCRF) copper accelerating structures using electron beam welding (EBW) instead of conventional high-temperature brazing. The core motivation is material performance: brazing softens copper significantly, while hard copper alloys have demonstrated ~75% higher operational gradients in SLAC tests, making cold-joining techniques highly attractive. EBW, applied to split-cell (half or quadrant) structure designs, preserves copper hardness away from the weld joint and simplifies machining — but industrial process optimization remains immature and a substantial learning curve is expected. The business case was modeled for two scenarios: a greenfield EBW linac company (> $10M upfront costs, viable above ~30 units/year) and an EBW division added to an existing accelerator firm to reduce risk and upfront costs, at the expense of being less optimal structure for the higher volume production. The study concludes that without a significant increase in demand, private investment alone cannot sustain this capability, and recommends federal support through R&D grants, procurement incentives, and CAPEX cost-sharing to incubate domestic EBW-NCRF manufacturing — with the existing-company model.

43 PARTICLE ACCELERATORS↗
DOE OSTI2022

Summary of Working Group 3: Laser and High-Gradient Structure-Based Acceleration

Accelerating particles at high gradients with high efficiencies is essential for reduction of size and cost of future accelerators for science and industry. This includes a future multi-TeV e+e- collider for particle, free-electron lasers for basic energy sciences and national security, industrial accelerators for energy and environmental applications, and accelerators for other applications. One way to achieve this is to use advanced externally-powered structures, both laser and RF driven. Working Group 3 (WG3) discussed novel accelerating structures with new geometries, new materials, frequencies from microwave to THz and optical spectrum, and operating conditions from room temperature to cryogenic. Presentations included recent advances in understanding RF breakdown and multipactor phenomena at different frequencies and materials, and other physics limitations to the accelerating gradient. Other relevant topics, such as developing high-gradient photoinjectors, high-efficiency RF power sources, and RF structures for a potential muon collider were discussed also. More details on each of the WG3 topics can be found in the articles published in these proceedings.

43 PARTICLE ACCELERATORS↗
DOE OSTI2020

Suppression of Deflecting Forces in Planar-Symmetric Dielectric Wakefield Accelerating Structures with Elliptical Bunches

Wakefield based accelerators capable of accelerating gradients two orders of magnitude higher than present accelerators offer a path to compact high energy physics instruments and light sources. However, for high gradient accelerators, beam instabilities driven by commensurately high transverse wakefields limit beam quality. It has been previously theoretically shown that transverse wakefields can be reduced by elliptically shaping the transverse sizes of beams in dielectric structures with planar symmetry. We report here experimental measurements that demonstrate reduced transverse wakefields for elliptical beams in planar symmetric structures which are consistent with theoretical models. Furthermore, these results may enable the design of gigavolt-per-meter gradient wakefield based accelerators that produce and stably accelerate high quality beams.

47 OTHER INSTRUMENTATION↗
DOE OSTI2025

Design Initiative for a 10 TeV pCM Wakefield Collider

This document outlines a community-driven Design Study for a 10 TeV pCM Wakefield Accelerator Collider. The 2020 ESPP Report emphasized the need for Advanced Accelerator R&D, and the 2023 P5 Report calls for the ``delivery of an end-to-end design concept, including cost scales, with self-consistent parameters throughout." This Design Study leverages recent experimental and theoretical progress resulting from a global R&D program in order to deliver a unified, 10 TeV Wakefield Collider concept. Wakefield Accelerators provide ultra-high accelerating gradients which enables an upgrade path that will extend the reach of Linear Colliders beyond the electroweak scale. Here, we describe the organization of the Design Study including timeline and deliverables, and we detail the requirements and challenges on the path to a 10 TeV Wakefield Collider.

43 PARTICLE ACCELERATORS↗
DOE OSTI2021

Long lifetime of bialkali photocathodes operating in high gradient superconducting radio frequency gun

Abstract High brightness, high charge electron beams are critical for a number of advanced accelerator applications. The initial emittance of the electron beam, which is determined by the mean transverse energy (MTE) and laser spot size, is one of the most important parameters determining the beam quality. The bialkali photocathodes illuminated by a visible laser have the advantages of high quantum efficiency (QE) and low MTE. Furthermore, Superconducting Radio Frequency (SRF) guns can operate in the continuous wave (CW) mode at high accelerating gradients, e.g. with significant reduction of the laser spot size at the photocathode. Combining the bialkali photocathode with the SRF gun enables generation of high charge, high brightness, and possibly high average current electron beams. However, integrating the high QE semiconductor photocathode into the SRF guns has been challenging. In this article, we report on the development of bialkali photocathodes for successful operation in the SRF gun with months-long lifetime while delivering CW beams with nano-coulomb charge per bunch. This achievement opens a new era for high charge, high brightness CW electron beams.

43 PARTICLE ACCELERATORS↗
DOE OSTI2022

R&D Towards High Gradient CW SRF Cavities

This talk will discuss Fermilab’s recent progress in the surface engineering of superconducting radio-frequency (SRF) cavities geared toward producing simultaneously high quality factors and high accelerating gradients in cryomodules. We investigate possible microscopic mechanisms that drive improved performance by carrying out sequential RF tests on cavities subjected to low temperature baking. We compare performance evolution to observations made with material science techniques and find correlations with material parameters. We also discuss other key advancements that enable high gradient operation in cryomodules.

43 PARTICLE ACCELERATORS↗
DOE OSTI2026

Correlating Surface Processing of Nb Superconducting RF Cavities with the Evolution of Surface Electronic States

Superconducting-radio frequency (RF) cavities provide an efficient way to accelerate particle beams with extremely high acceleration gradients while generating very small power dissipation. The few nanometers of the surface play a critical role in defining the RF performance of superconducting Nb based cavities. Over the past two decades, several pioneering surface treatment and processing methods have emerged, enabling remarkable improvements in superconducting cavity performance by simultaneously achieving high quality factors with increasing maximum acceleration gradients. These processing approaches include chemical polishing, distinct multi-step thermal treatments under ultra-high vacuum (UHV) conditions over low to high temperature regimes, as well as high-temperature treatments under controlled nitrogen atmospheres. Beyond their macroscopic impact on RF performance, these methods produce distinct surface oxide configurations characterized by different valence states, oxide thicknesses, chemical uniformity, and oxygen concentration profiles extending into the near-surface bulk of niobium. In this work, we are trying to understand how the surface-processing methods and the resulting oxide/oxygen profiles affect the electronic structure of surface and the mechanism of superconductivity. Using a combination of X-ray photoemission and X-ray absorption spectroscopies, we investigate how the valence-band structure and the electronic density of states (DoS) near the Fermi level evolve under different surface treatments. By employing tunable photon energies across multiple elemental absorption edges, we use resonant photoemission to disentangle and identify the elemental contributions to specific valence-band features. Our observations show that different surface-processing methods lead to distinct temperature evolutions of the DoS and valence-band states near the Fermi level. Our results suggest variations in different Nb-O orbital hybridizations in distinct processes and point towards the possibility of different underlying mechanisms of superconductivity governed by surface chemistry and oxide configuration. We also correlate these distinct superconducting mechanisms with RF cavity performance, specifically focusing on measured surface resistance, the nature of the Q-slope, and quench fields observed in superconducting RF measurements. These results will enable us to identify the potential limiting factors and relevant controllable parameters that can be further optimized to improve the performance of superconducting RF cavities.

Tripathi, Malvika [Fermilab] (ORCID:00000001989251↗
DOE OSTI2021

Measurements of Magnetic Field Penetration in Superconducting Materials for SRF Cavities

Superconducting radiofrequency (SRF) cavities used in particle accelerators operate in the Meissner state. To achieve high accelerating gradients, the cavity material should stay in the Meissner state under high RF magnetic field without penetration of vortices through the cavity wall. The field onset of flux penetration into a superconductor is an important parameter of merit of alternative superconducting materials other than Nb which can enhance the performance of SRF cavities. There is a need for a simple and efficient technique to measure the onset of field penetration into a superconductor directly. We have developed a Hall probe experimental setup for the measurement of the flux penetration field through a superconducting sample placed under a small superconducting solenoid magnet which can generate magnetic fields up to 500 mT. The system has been calibrated and used to measure different bulk and thin film superconducting materials. This system can also be used to study SIS multilayer coatings that have been proposed to enhance the vortex penetration field in Nb cavities.

Senevirathne, I. H.↗
DOE OSTI2025

Numerical Analysis of High-Order Modes in SRF Resonators for Particle Accelerators

Over the past decades, superconducting technology has rapidly evolved towards high accelerating gradients and low surface resistance, making it possible to operate particle accelerators with high average beam currents and large duty factors. However, RF losses due to coherent excitation of the HOM become the limiting factor for these regimes. Unlike the cavity operating mode, which is tuned separately, the HOM parameters can significantly vary from one cavity to another due to finite mechanical tolerances during the manufacturing process. Thus, it is of utmost importance to know the HOM parameter spread in advance in order to predict unexpected cryogenic losses, overheating of beam line components and maintain stable beam dynamics. In this paper, we present a method for generating cavity geometry with an arbitrary spread of mechanical imperfections and numerically evaluating HOM statistics. Knowing the spread of HOM parameters, we calculated the probability of resonant HOM losses in SRF accelerating cavities used in CW beam current machines such as the PIP-II and LCLS-II linacs, as well as for the SRF crab-cavity for the ILC project. Finally, we present experimental results of HOM spectra measurements in hundreds of 1.3 GHz cavities installed in LCLS-II cryomodules. Studying the effects of HOM excitation results in specifications of the SRF cavity and cryomodule and can significantly impact the efficiency and reliability of the machine operation.

Lunin, Andrei [Fermilab] (ORCID:0000000290096792)↗
DOE OSTI2022

On possibility of low-emittance high-energy muon source based on plasma wakefield acceleration

We report plasma wakefield acceleration (PWA) channels are characterized by very high accelerating gradients and very strong focusing fields. We propose to employ these properties for effective production of low emittance high energy muon beams, consider muon beam dynamics in the PWFA cell and analyze various options and potential of the PWA-based muon sources.

43 PARTICLE ACCELERATORS↗
DOE OSTI2020

High-Brightness Continuous-Wave Electron Beams from Superconducting Radio-Frequency Photoemission Gun

Continuous-wave photoinjectors operating at high accelerating gradients promise to revolutionize many areas of science and applications. They can establish the basis for a new generation of monochromatic x-ray free electron lasers, high-brightness hadron beams, or a new generation of microchip production. In this Letter we report on the record-performing superconducting rf electron gun with CsK 2 Sb photocathode. The gun is generating high charge electron bunches (up to 10 nC / bunch ) and low transverse emittances, while operating for months with a single photocathode. As such, this achievement opens a new era in generating high-power beams with a very high average brightness.

43 PARTICLE ACCELERATORS↗
DOE OSTI2020

History of gradient advances in SRF

Radio frequency (RF) superconductivity has become a key technology for many modern particle accelerators. One of its most salient features of this technology is the ability of superconducting RF cavities to deliver high accelerating gradients in continuous-wave and long-pulse modes of operation. However, reaching the current state of the technology was not an easy fit. Over many years scientists and engineers had to overcome several serous performance limitations. In this paper, I attempt to the best of my knowledge to trace the history of accelerating gradients evolution in the field of superconducting radio frequency. I will restrict the scope to primary innovations along with some of the ensuing developments in developing cavities made of bulk niobium. But I will not cover all the many applications and findings over the subsequent decades of progress that were based on the primary discoveries and inventions. I will also not cover a number of other important topics in the history of cavity developments, such as the drive for higher Q values, or the push for lower cavity costs via Nb/Cu cavities or large grain Nb cavities.

43 PARTICLE ACCELERATORS↗
DOE OSTI2020

High Dynamic Voltage Range Studies of Piezoelectric Multilayer Actuators at Low Temperatures

Piezo actuators are used for resonance control in superconducting linacs. In high accelerating gradients linacs, such as those operated in a pulsed mode, the piezos require a large operating voltage. This is due to the Lorentz forced detuning which causes a large frequency shift and is compensated with an active piezo-tuning system. In this high dynamic voltage range the piezo is expected to warm up drastically due to it being in an insulated vacuum. This study characterizes the dielectric properties (capacitance, dielectric losses), the piezo stroke (from geophone), and thermal properties such as heating. Results obtained in the temperature range of 20K to 300K will be presented and discussed.

43 PARTICLE ACCELERATORS↗
DOE OSTI2025

Focusing of relativistic electron beams with permanent magnetic solenoid

Achieving strong focusing of MeV electron beams is a critical requirement for advanced beam applications such as compact laboratory x-ray sources, high gradient accelerators, and ultrafast electron scattering instrumentation. To address these needs, a compact radially magnetized permanent magnetic solenoid (PMS) has been designed, fabricated, and tested. The solenoid provides a compact and inexpensive solution for delivering high axial magnetic fields (1 T) to focus MeV electron beams. Field characterization of the solenoid demonstrates good agreement with analytical models, validating the PMS design. The electron beam test employs a high-brightness photoinjector to study the focusing properties of the PMS. The results indicate a focal length of less than 10 cm and a significant reduction in beam size with small spherical aberrations. Two application cases are evaluated: angular magnification in ultrafast electron diffraction setups and strong focusing for Compton scattering or other microfocus uses.

Electron diffraction↗
DOE OSTI2021

Development of High-efficiency and Cost-effective Forged Ingot Niobium Technology for Science Frontiers and Accelerator Applications

Development of Forged Ingot Niobium Technology: Worlds science frontier programs and SRF accelerator applications demand high performance and cost-effective SRF accelerator technology [1-8]. Fine-grain (FG) and Large-grain (LG) ingot niobium technologies have been very well developed and implemented in all the present-day accelerator projects. However, forged ingot niobium technology which is the focus of this development proposal will be much more cost-effective and expected to have several technical advantages. FG niobium sheet production is very complex involving more than ten processing steps making them prone to contamination. As a result, they are very expensive to produce and require stringent QA procedure to be ready for SRF cavity production. The accelerating cavity process steps are also numerous and require strict procedures in order to achieve high accelerating gradients and quality factors needed for science frontier programs. LG niobium disc production, directly sliced from the ingot, is relatively simple and straight forward to keep surface cleanness. The disc production cost is significantly low compared to FG niobium sheet production. However, there are (some) draw backs due to non-homogeneity of the grain boundary distribution, resulting in non-uniform mechanical properties and complex cavity fabrication, although the LG cavities achieve the expected high-gradient performance goals with lower cost. Medium-grain (MG) niobium disk production may be realized with a new approach/process, the disc directly sliced from the forged ingot, involves a simpler process steps contributing major production cost reduction [9]. These discs are expected to be superior as they tend to be homogenous with uniform sub millimeter grains and mechanical properties. We are eagerly looking forward to developing the forged ingot niobium SRF accelerator technology for the benefit of the world-wide science frontier programs, green energy subcritical nuclear energy systems and a wide variety of industrial applications including the production of radio isotopes and nuclear transmutation applications. Measurement of thermal characteristics of the forged ingot niobium: Measurement of the thermal diffusivity, D, of superconducting MG niobium is important to be understood in comparison with FG sheet and LG disc, as well as that of advanced composite material of Nb3Sn film sputtered on forged ingot Nb, which will be determined using transient pump-probe thermo-modulation [10,11]. Transient thermo-modulation is based on using an ultrafast laser pulse to heat the superconducting materials by a few K, then a synchronized laser pulse probes the reflectance of the heated material. For thin films on a substrate (e.g, 100-nm Nb3Sn on Nb), it takes <100 ps for the heat to reach the substrate by diffusion. Therefore, an ultrafast method is needed to probe D of the studied material. D will be measured from room temperature to liquid helium temperatures. Fundamental Research: The increase of rf loss in SRF cavities is related to trapping of residual magnetic field during the cavity cool-down. The study suggested that the micro structure plays the role in flux trapping sensitivity. The research includes the flux trapping and expulsion study as forged ingot niobium goes through several mechanical deformations, crystallization leading to the optimal SRF cavity performance. Furthermore, the cavity made from FG, MG, and LG sheet/disc will be compared to understand the optimal re-crystallization temperature that cavity needed to be heat treated which minimize the flux trapping and increase SRF cavity performance. References: 1. S. Belomestnykh, Overview of recent SRF developments for ERLs, presented at the SRF 2015, Whistler, BC, Canada (2015). 2. A. Yamamoto, M. Yamanaka and G. Myneni, Ingot Nb based SRF Technology for the International Linear Collider, in Science and Technology of Ingot Niobium for Superconducting Radio Frequency Applications, AIP Conf. Proc. 1687, 030005-1 ? 03005-6, 2015 3. Report of the Workshop on Energy and Environmental Applications of Accelerators, DOE Workshop Report. https://science.osti.gov/-/media/hep/pdf/Reports/2020/CASM_WorkshopReport.pdf? la=en&hash=AEB0B318ED0436B1C5FF4EE0FDD6DEB84C2F15B2 4. G. Ciovati, et al., Design of a cw, low-energy, high-power superconducting linac for environmental applications, Phys. Rev. Accel. Beams 21, 091601 (2018). 5. P. Dhakal, et al., Effect of high temperature heat treatments on the quality factor of a large-grain superconducting radio-frequency niobium cavity, Phys. Rev. ST Accel. Beams 16, 042001 (2013). 6. P. Kneisel et al., Review of ingot niobium as a material for superconducting radio frequency accelerating cavities, Nuclear Instruments and Methods in Physics Research A 774, 133 (2015). 7. G. Ciovati, P. Dhakal, and G. R, Myneni, Superconducting radio-frequency cavities made from medium and low-purity niobium ingots, Supercond. Sci. Technol. 29, 064002 (2016). 8. M. Drury et al., commissioning of the prototype C75 cavities in a CEBAF cryomodule, in Proc. of IPAC 2018, Vancouver, BC, Canada (2018) 9. Feasibility of forged-ingot niobium disc and SRF cavity fabrication technology recently demonstrated in cooperation of ATI, BSCE, and KEK (2020). 10. Hani E. Elsayed-Ali, ?Measurements of heat transport in thin films by ultrafast laser-based techniques,? 3rd International Conference on Thermal Issues in Emerging Technologies Theory and Applications, Cairo, Egypt, pp. 347 ? 350 (2010). DOI: 10.1109/ThETA17616.2010 11. W. M. G. Ibrahim, H. E. Elsayed-Ali, M. Schinn, and C. A. Bonner, Jr., ?Ultrafast investigation of electron dynamics in multilayer metals,? Int. J. Heat and Mass Transfer, 47(10?11), 2261?2268 (2004).

Myneni, G.↗
DOE OSTI2022

Vacuum laser acceleration of super-ponderomotive electrons using relativistic transparency injection

Abstract Intense lasers can accelerate electrons to very high energy over a short distance. Such compact accelerators have several potential applications including fast ignition, high energy physics, and radiography. Among the various schemes of laser-based electron acceleration, vacuum laser acceleration has the merits of super-high acceleration gradient and great simplicity. Yet its realization has been difficult because injecting free electrons into the fast-oscillating laser field is not trivial. Here we demonstrate free-electron injection and subsequent vacuum laser acceleration of electrons up to 20 MeV using the relativistic transparency effect. When a high-contrast intense laser drives a thin solid foil, electrons from the dense opaque plasma are first accelerated to near-light speed by the standing laser wave in front of the solid foil and subsequently injected into the transmitted laser field as the opaque plasma becomes relativistically transparent. It is possible to further optimize the electron injection/acceleration by manipulating the laser polarization, incident angle, and temporal pulse shaping. Our result also sheds light on the fundamental relativistic transparency process, crucial for producing secondary particle and light sources.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS1995

Development work for a superconducting linear collider

For future linear e(+)e(-) colliders in the TeV range several alternatives are under discussion. The TESLA approach is based on the advantages of superconductivity. High Q values of the accelerator structures give high efficiency for converting RF power into beam power. A low resonance frequency for the RF structures can be chosen to obtain a large number of electrons (positrons) per bunch. For a given luminosity the beam dimensions can be chosen conservatively which leads to relaxed beam emittance and tolerances at the final focus. Each individual superconducting accelerator component (resonator cavity) of this linear collider has to deliver an energy gain of 25 MeV/m to the beam. Today s.c. resonators are in use at CEBAF/USA, at DESY/Germany, Darmstadt/Germany KEK/Japan and CERN/Geneva. They show acceleration gradients between 5 MV/m and 10 MV/m. Encouraging experiments at CEA Saclay and Cornell University showed acceleration gradients of 20 MV/m and 25 MV/m in single and multicell structures. In an activity centered at DESY in Hamburg/Germany the TESLA collaboration is constructing a 500 MeV superconducting accelerator test facility (TTF) to demonstrate that a linear collider based on this technique can be built in a cost effective manner and that the necessary acceleration gradients of more than 15 MeV/m can be reached reproducibly. The test facility built at DESY covers an area of 3.000 m2 and is divided into 3 major activity areas: (1) The testlinac, where the performance ofthe modular components with an electron beam passing the 40 m long acceleration section can be demonstrated. (2) The test area, where all individual resonators are tested before installation into a module. (3) The preparation and assembly area, where assembly of cavities and modules take place. We report here on the design work to reach a reduction of costs compared to actual existing superconducting accelerator structures and on the facility set up to reach high acceleration gradients in a reproducible way.

Matheisen, Axel↗