The strip casting of steel, whereby liquid steel is solidified between twin water cooled copper rolls directly into its final shape, is a radical, energy efficient, cost effective route for the production of steel products that also provides exciting opportunities for the development of new products. An experimental program is currently underway to study phenomena associated with rapid solidification of steel using levitating droplet techniques and Gleeble®3500 thermo-mechanical processing. For example, studies have been conducted to investigate the heat transfer, nucleation behaviour and microstructure development during solidification of a low carbon steel and a peritectic steel on copper substrates hard coated electrolytically or using Filtered Arc Deposition (FAD). It was found that peak and average heat fluxes were significantly higher for steels solidified on the first substrate than for the FAD coated substrates. Maximum heat flux on the respective substrates was 36.5 to 39.0 MW/m2 and 8.3 to 9.4 MW/m2. The average heat flux on the respective coated substrates ranged between 9.6 to 12.5 and 5.5 to 6.6 MW/m2.