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Abstract While Nb₃Sn theoretically offers better superconducting radio-frequency (RF) cavity performance (Q₀and $E_{\mathrm{acc}}$) to Nb at any given temperature, peak RF magnetic fields consistently fall short of the ∼400 mT prediction. The relatively rough topography of vapor-diffused Nb₃Sn is widely conjectured to be one of the factors that limit the attainable performance of Nb₃Sn-coated Nb cavities prepared via Sn vapor diffusion. Here we investigate the effect of coating duration on the topography of vapor-diffused Nb₃Sn on Nb and calculate the associated magnetic field enhancement and superheating field suppression factors using atomic force microscopy topographies. It is shown that the thermally grooved grain boundaries are major defects which may contribute to a substantial decrease in the achievable accelerating field. The severity of these grooves increases with total coating duration due to the deepening of thermal grooves during the coating process. 

The trapped residual magnetic flux during the cool-down due to the incomplete Meissner state is a significant source of radio frequency losses in superconducting radio frequency cavities. Here, we clearly correlate the niobium microstructure in elliptical cavity geometry and flux expulsion behavior. In particular, a traditionally fabricated Nb cavity half-cell from an annealed poly-crystalline Nb sheet after an 800 C heat treatment leads to a bi-modal microstructure that ties in with flux trapping and inefficient flux expulsion. This non-uniform microstructure is related to varying strain profiles along the cavity shape. A novel approach to prevent this non-uniform microstructure is presented by fabricating a 1.3 GHz single cell Nb cavity with a cold-worked sheet and subsequent heat treatment leading to better flux expulsion after 800 ^∘C/3 h. Microstructural evolution by electron backscattered diffraction-orientation imaging microscopy on cavity cutouts, and flux pinning behavior by dc-magnetization on coupon samples confirms a reduction in flux pinning centers with increased heat treatment temperature. The heat treatment temperature-dependent mechanical properties and thermal conductivity are reported. The significant impact of cold work in this study demonstrates clear evidence for the importance of the microstructure required for high-performance superconducting cavities with reduced losses caused by magnetic flux trapping.