The present study explores the feasibility of replacing conventional silica sand with industrial waste–based moulding materials—blast furnace slag and ferrochrome slag—in the CO₂ casting of AA2024 aluminium alloy. Alternative mold media have been shown in earlier research to improve cooling behavior and lessen environmental impact; however, AA2024 alloy and its tribo-mechanical response have received little attention. The impact of these molding sands on wear behavior, surface finish, mechanical characteristics, and microstructural features was methodically assessed in this study. According to thermal analysis, ferrochrome slag produced refined grain structures (~75 µm) by promoting faster heat dissipation. As a result, silica sand castings exhibited the highest tensile strength due to their relatively balanced solidification and lower internal stress levels. In contrast, ferrochrome slag castings demonstrated superior microhardness and enhanced wear resistance. Due to the strong strain-hardening effect, blast furnace slag showed increased compressive strength. Slag-based molds deliver competitive performance with enhanced durability under sliding conditions, as demonstrated by surface roughness and tribological evaluations