High silicon steel was fabricated by twin-roll strip casting. The cracks on the surfaces of the processed strips were obtained and analyzed by digital camera after series of surface treatment. Optical microscopy (OM) and scanning electron microscopy (SEM) were used to observe and characterize the microstructure nearby crack and fracture surface along the normal direction, respectively, and the crack formation mechanism was further analyzed in conjunction with processing parameters utilized during twin-roll strip casting process. The results indicated that morelongitudinal cracks along the rolling direction were observed in comparison with transverse cracks along the transverse direction on the strip surfaces. Trans granular and intergranular fracture modes both worked during the formations of longitudinal and transverse cracks on the processed strips. The dominant factor causing the formation of crack on the surface of the processed strips was the inhomogeneous transfer of heat during casting and rolling. The inhomogeneous transfer of heat induced by gas gap during casting resulted in variations of dendrite length and secondary dendrite spacing (SDAS). Meanwhile, the casting velocity influenced the formation of gas gap, which further influenced the thermal contraction. So the control of velocity of casting above a certain level proved beneficial to enhancing the performance of strip casting and to improving the quality of strip products.
