In friction drilling, a revolving conical tool softens and penetrates a thin workpiece using the heat produced by friction to form a bushing without producing chips. This study examines tool wear in friction drilling, a non-conventional method of creating holes. Tool wear is essential in friction drilling since it has an impact on the achievable tolerances. This study examined the tool wear properties of Al alloy and was subjected to experimental friction drilling with a tungsten carbide tool to investigate. Wear of the tool’s changes were measured to quantify the attributes by weight reduction and tool form. This research illustrates a method for tracking the condition of a tool during friction drilling, according to the accelerometer sensors’ vibration data. After the accelerometer sensors captured the signals, the raw data were filtered using a low-pass filter. According to the findings, tool wear in the drilling process is supported by the fact that tool wear and friction have a direct correlation with vibration amplitude. The thrust forces required for friction drilling at different feed rates and speeds are tracked using a drill tool dynamometer. A scanning electron microscope (SEM) is used to analyze the microscopic observations of the drilled holes. The thrust forces gradually increased when feed rates were maintained at a constant speed. In the case of aluminum, the microstructure photographs demonstrated strong workpiece adhesion and material transfer.