The effect of casting temperature, cooling rate in silica bound molding sand and modifier additions on tensile, ductility and hardness properties Al-Cu binary alloy is presented. The study revealed that casting at high cooling rate and low casting temperatures with sufficient addition of ferro-silicon not exceeding the limited concentration for solubility improve mechanical properties of castings. The study also indicated that casting temperature greater than 7000C expanded the liquidussolidus solidification line leading to multiple phase formation which in-turn affect the final microstructure. Casting temperature of 7000C, addition of modifier in amount up to 200g and rapid cooling rate optimized the mechanical properties. The microstructure in this condition consists of equiaxed grains with spot presence of CuAl2 intermetallics which probably is responsible for the increased tensile strength and marginal change in ductility.