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The heat transfer occurring on boundary layer flows during dilute suspension of Cu–Al2O3 nanoparticles-based non-Newtonian Casson hybrid nanofluid over diverging channel is to be characterized in this model. The governing equations comprise continuity, momentum, energy and concentration equations which incorporated variable viscosity and magnetic effects in the momentum equation, variable thermal conductivity, chemical reaction, thermal radiative heat flux, uniform magnetic field, Joule heating and viscous dissipative effects in the energy equation and Brownian motion and thermophoretic effects in the concentration equation. The modeled equations are nondimensionalized using nonsimilar variables and linearized using quasilinearization technique. The system of linearized partial differential equations is solved numerically using implicit finite difference and successively iterated with the help of Varga's algorithm. The physical impacts of viscous dissipation parameter (Ec), Brownian motion ( N b ) on velocity, temperature, concentration and Schmidt number (Sc) influences on skin friction, Nusselt number, Sherwood number profiles, Bejan lines and total entropy production profiles are simulated graphically. The velocity profiles are enhanced and the temperature profile declines for augmented values of Eckert number. Moreover, for augmented values of Schmidt number the heat and mass transfer rates are enhanced and the Bejan lines dropped a decreasing trend whereas total entropy production is augmented near the wall region. The improved values of the Schmidt number physically increased Sc in the heat transfer rate. The ascending profile of the mass transfer rate with increased values of the viscous dissipation parameter Ec demonstrated that the graph is raised for larger values of the viscous dissipating parameter (Ec). The physical behavior of incremental mass transfer rate led to the conclusion that the relative diffusivity of nanoparticles is characterized by both nondimensional numbers Ec and Sc which are directly proportional to the viscous forces. [ABSTRACT FROM AUTHOR]