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In thermal friction drilling (TFD) operations, the geometrical dimensions of bushing shape, height and wall thickness are the most vital consequences, due to increasing the connecting length and strength. In this paper, AA7075-T651 aluminum alloys with 2, 4, 6, 8, and 10 mm in thicknesses were drilled with TFD process in order to investigate the density, the volume ratio, and height and wall thickness of the bushings. The experiments were conducted at constant spindle speed and feed ratedoi:10.20944/preprints201811.0263.v1 fatcat:z2ykc2ee55cznewzoeb7fog52a