The twin-roll process is modeled by a coupled fluid how and phase change model by means of a versatile finite element method. The multidomain method is employed to deal with the solid and liquid phases separately; which includes treating the liquid phase as an Newtonian fluid and the solid phase as a viscoplastic metal. Furthermore, a simple and efficient method is used for overcoming the difficulty of remesh phase encountered during iteration. From the results of this study, the inlet region must be included in the analysis for obtaining the reliable flow field within the strip. In addition, the circulation occurs in the molten region and it is driven mainly by the rotating rollers. Finally, the interface position and shape are both influenced by the inlet flow rate and angular speed of rollers. (C) 1997 Elsevier Science Ltd.