Here's a list I compiled from notstarring.com and a little research.
1. Salt (2010)
Tom Cruise was originally considered for this movie. Yet, he backed out of doing the espionage thriller, the script for which was originally titled "Edwin A. Salt." An article from filmschoolrejects.com states that for reasons known only to him and his dietitian, Tom Cruise has decided to pass on Edwin A. Salt, the CIA spy thriller that has also seen at least four big name directors come and go in the past year. With Cruise out, though, Columbia Pictures is turning to the next obvious choice to take his place: Angelina Jolie. Thus, it was retitled "Salt", for Evelyn Salt.
2. Inception (2010)
James Franco, a Golden Globe Award-winning American actor, director, screenwriter, film producer, and artist, was originally considered for playing mind thief Leonardo DiCaprio's working partner in Christopher Nolan's massive film. Yet, he dropped out of this movie because of "scheduling conflicts."
The actor who got the part: Joseph Gordon-Levitt.
3. The Last Airbender (2010)
Director M. Night Shyamalan initially considered Ben Kingsley for the role of Uncle Iroh.
Actor who got the part: Shaun Toub.
Jesse McCartney was originally cast as Prince Zuko, but dropped out due to conflicts with his music career.
Actor who got the part: Dev Patel.
4. Iron Man 2 (2010)
Emily Blunt was initially considered for the role of Black Widow in the movie, and not Eliza Dushku nor Anne Hathaway. According to an article from obsessedwithfilm.com, 20th Century Fox has used their pre-agreed option from THE DEVIL WEARS PRADA to nab actress Emily Blunt for one of their tentpoles, casting her in GULLIVER’S TRAVELS, the upcoming adventure comedy starring Jack Black.
Actor who got the part: Scarlett Johansson.
5. Avatar (2009)
Emily Blunt auditioned for the role of Neytiri but James Cameron preferred a relatively unknown actress.
Charisma Carpenter was set to star as Neytiri when the film began to be developed around 1995, but by the time of filming she was no longer age appropiate.
Actor who got the part: Zoe Saldana.
6. The Blind Side (2009)
Julia Roberts was originally the film's first choice to play the Leigh Anne Tuohy, the role that earned Bullock an Oscar for Actress in a Leading role.
Actor who got the part: Sandra Bullock.
7. Drag Me to Hell (2009)
Ellen Page, a Canadian actress, was considered for the lead role of the film. Due to the writer's strike, the film had to be rushed into production and it conflicted with Page's schedule.
Actor who got the part: Alison Lohman.
8. The Hangover (2009)
Lindsay Lohan was offered the role of an escort named "Jade" but turned it down because she thought the screenplay "had no potential" and she didn't like the script.
Actor who got the part: Heather Graham.
9. Nine (2009)
Johnny Depp was mentioned as a possibility to star as the Fellini-esque Italian director in the movie version of the Broadway musical.
Actor who got the part: Daniel Day-Lewis.
Cameron Diaz and Kristen Stewart auditioned for the role of Stephanie, but were turned down from the role for being too old and unfit...
Actor who got the part: Kate Hudson.
Mary Stuart Masterson played Luisa in the Broadway revival of the musical. She won a Drama Desk Award for her performance, but was not cast in the final film.
Actor who got the part: Nicole Kidman.
10. Shutter Island (2010)
Sylvester Stallone turned down the role of Chuck Aule.
Actor who got the part: Mark Ruffalo.
11. The Ghosts of Girlfriends Past (2009)
Ben Affleck was originally announced by Disney to star in the Charles Dickens'-inspired comedy as a playboy bachelor. Affleck suffered loss of career status after the failure of "Gigli" and became of less interest to the studio.
Actor who got the part: Matthew McConaughey.
12. State of Play (2009)
Brad Pitt was originally considered for the lead role but he withdrew from the production purportedly because he was not happy with the screenplay.
Johnny Depp and Tom Hanks were two of the actors considered when Brad Pitt dropped out.
Actor who got the part: Russell Crowe.
When production stalled due to Brad Pitt dropping out, Edward Norton was forced to also drop out due to scheduling conflicts.
Actor who got the part: Ben Affleck.
13. The Curious Case of Benjamin Button (2008)
Tom Cruise was initally attached as the lead in the 90s, when Steven Spielberg was set to direct. According to IMDB, Steven Spielberg was attached to the film, in the late 1990s. He would have had Tom Cruise star. In October 1998, screenwriter Robin Swicord wrote for director Ron Howard an adapted screenplay of the short story, a project which would potentially star actor John Travolta. Yet, in July 2005, David Fincher negotiated a deal with the studios to direct the film.
Actor who got the part: Brad Pitt.
According to IMDB, Rachel Weisz was considered the role of Daisy, but turned it down because of scheduling conflicts.
Actor who got the part: Cate Blanchett.
14. The Dark Knight (2008)
Matt Damon reportedly turned down the role of Harvey Dent.
Actor who got the part: Aaron Eckhart.
Katie Holmes turned down the chance to reprise the role of Rachel Dawes in this sequel to the hit "Batman Begins". Abbie Cornish was considered for the role of Rachel Dawes after Katie Holmes departed.
Actor who got the part: Maggie Gyllenhaal.
Robin Williams, Sam Rockwell, Paul Bettany and Adrien Brody were considered for the role of the Joker.
Actor who got the part: Heath Ledger.
15. Twilight (2008)
Henry Cavill was novelist Stephenie Meyer's choice to play the handsome vampire in the movie version of her best-seller. By the time filming began, Cavill was too old to play a high school guy.
Actor who got the part: Robert Pattinson.
Sara Paxton auditioned for the lead role.
Actor who got the part: Kristen Stewart.
* Published on 6/10/11,