Motivated by the desire to develop a single-shot drill and fasten system for temporary in-field repairs using a bolted composite doubler repair on metallic thin shell structures, a novel approach for drilling composite-metal stacks is proposed wherein a friction flow drilling (FFD) bit is covered with a frangible abrasive coating. In order to demonstrate its feasibility, drilling of composite-metal stacks with predrilled holes in the composite is investigated. The goals were to understand the processes involved in FFD in metals and effects of process and design parameters on forming a metal bushing and collar for the composite laminate to enable fastening of the entire composite/metal stack. Effects of composite hole clearance, metal thickness, feed rates, and spindle speeds of the FFD tool bit on forming a bushing and collar around the composite were investigated. Results support the feasibility of the proposed design where mechanisms that drive the formation of bushings and collars are identified and the effects of key drilling parameters needed for successful drilling are described.