The 0.15, 0.2, 0.3, and 0.5 mm-thick 6.5 wt.% Si electrical steel sheets were produced by twin-roll strip casting, hot rolling, warm rolling, and annealing. A detailed study of the microstructure and texture evolution at different processing stages was carried out by optical microscopy and X-ray diffraction. The initial as-cast strip showed strong columnar grains and pronounced < 001 >//normal direction (ND) texture. The hot rolled sheet with an inhomogeneous microstructure demonstrated slightly weakened < 001 >//ND texture. The morphology of the warm rolling microstructure could be classified into two types. One was characterized by large amounts of in-grain shear bands (0.5 mm-thick sheet), whereas the other was constituted of the mixture of newly recrystallized grains and severely deformed grains (0.15-0.3 mm-thick sheets). The warm rolling texture was dominated by < 110 >//rolling direction and < 111 >//ND textures. The intensities of the < 111 >//ND textures were higher in the 0.15-0.3 mm-thick warm rolled sheets. After annealing, the 0.5 mm-thick sheet showed < 001 >//ND, parallel a-fiber, and very weak < 111 >//ND textures, whereas the 0.15-0.3 mm-thick sheets presented strong < 111 >//ND texture. The magnetic inductions of the 0.3 and 0.5 mm-thick sheets were superior to those of the corresponding CVD products.