Nanofluids possess unique thermal and rheological properties that offer significant advantages in enhancing heat transfer efficiency in various applications, such as heat exchangers, cooling systems, and microdevices. In this study, we investigate the combined effects of thermal radiation, Joule heating, variable viscosity, and a two-phase model on the flow behavior and heat transfer characteristics of a magnetohydrodynamic Casson nanofluid flowing over a stretching sheet in Darcy-Forchheimer porous media. The governing partial differential equations are converted into a system of first-order ordinary differential equations numerically solved using the bvp5c package in MATLAB. Consequently, the result indicates that the velocity profile increases with thermal radiation, variable viscosity, and viscous dissipation, decreasing with the magnetic field, permeability index, and Forchheimer coefficient. Also, the temperature profile shows an increase with the permeability index, viscous dissipation, and thermal radiation, but a decrease with the Forchheimer Coefficient, variable viscosity, and magnetic field. Additionally, the concentration profile exhibits an increase with the Forchheimer coefficient and permeability index, and variable viscosity while it decreases with viscous dissipation, magnetic field, and thermal radiation. Analyzing the skin friction coefficient reveals an increase with magnetic field and thermal radiation and a decrease with permeability index and Forchheimer coefficient as well as variable viscosity. Moreover, the local heat transfer rate demonstrates an increase with the variable viscosity, and magnetic field as well as the Forchheimer coefficient and permeability index. At the same time, it decreases with the viscous dissipation. Furthermore, the local mass transfer rate displays an increase with the magnetic field and thermal radiation and viscous dissipation, while it decreases with the variable viscosity as well as permeability index, viscous dissipation, and Forchheimer coefficient. Finally, the current findings are compared with that of the existing literature and a sound agreement was established.