Smooth, homogeneous, high-purity Nb₃Sn superconducting RF resonant cavity by seed-free electrochemical synthesis

Workbench-size particle accelerators, enabled by Nb₃Sn-based superconducting radio-frequency (SRF) cavities, hold the potential of driving scientific discovery by offering a widely accessible and affordable source of high-energy electrons and x-rays. Thin-film Nb₃Sn RF superconductors with high quality factors, high operation temperatures, and high-field potentials are critical for these devices. However, surface roughness, non-stoichiometry, and impurities in Nb₃Sn deposited by conventional Sn-vapor diffusion prevent them from reaching their theoretical capabilities. Here we demonstrate a seed-free electrochemical synthesis that pushes the limit of chemical and physical properties in Nb₃Sn. Utilization of electrochemical Sn pre-deposits reduces the roughness of converted Nb₃Sn by five times compared to typical vapor-diffused Nb₃Sn. Quantitative mappings using chemical and atomic probes confirm improved stoichiometry and minimized impurity concentrations in electrochemically synthesized Nb₃Sn. We have successfully applied this Nb₃Sn to the large-scale 1.3 GHz SRF cavity and demonstrated ultra-low BCS surface resistances at multiple operation temperatures, notably lower than vapor-diffused cavities. Our smooth, homogeneous, high-purity Nb₃Sn provides the route toward high efficiency and high fields for SRF applications under helium-free cryogenic operations.