Process and apparatus for forming wire from powder materials

A process for producing a wire from powder particles, the process comprising:

• consolidating a loose powder within a passage by subjecting the loose powder to microwave radiation while particles of the loose powder are not bonded to each other and as the loose powder flows through the passage, the loose powder consisting of particles formed of metallic, intermetallic and/or ceramic materials and of a size and composition that render the particles susceptible to microwave radiation, the loose powder within the passage being subjected to microwave radiation so that the particles thereof couple with the microwave radiation and are sufficiently heated to melt at least a radially outermost quantity of the particles within the passage, wherein the passage is formed of a material substantially transparent to microwave radiation and the microwave radiation passes through the passage before heating the particles within the passage;
• and then
• cooling the particles so that the radially outermost quantity of the particles solidifies to yield a wire comprising a consolidated outermost region surrounding an interior region of the wire.