Abstract: A method of forming an earth-boring tool includes introducing metal into a die, rotating the die to generate centrifugal forces on the metal, and cooling the metal in the rotating die. A rotary drill bit may include a unitary, centrifugally cast bit body including an integral shank, at least one blade, and at least one cutting element on the blade. A rotary drill bit or a roller cone may include a first centrifugally cast material and a second centrifugally cast material. Another rotary drill bit includes a bit body comprising a maraging steel alloy. A method of forming a rotary drill bit may include disposing cutting elements on a rotary drill bit comprising maraging steel and aging the rotary drill bit to form at least one intermetallic precipitate phase. Methods of repairing a rotary drill bit include annealing and aging at least a portion of a rotary drill bit.

Abstract: The disclosure, in one aspect, provides a method of drilling a wellbore that includes features of drilling the wellbore using a drilling assembly that includes a drill bit that further includes a weight sensor and a torque sensor, determining weight-on-bit using measurements from the weight sensor and torque-on-bit using measurement from the torque sensor during drilling of the wellbore, obtaining measurements for rotational speed of the drill bit and rate of penetration of the drill bit during drilling of the wellbore, determining mechanical specific energy of the bottomhole assembly using the determined weight-on-bit, torque-on-bit and obtained rotational speed of the drill bit and the obtained rate of penetration of the drill bit, and altering a drilling a parameter in response to the determined mechanical specific energy.

Abstract: A cutting element for an earth-boring tool includes a body having a longitudinal axis, a generally planar volume of hard material carried by the body, and a sensor affixed to the body. The sensor may be configured to sense at least one of stress and strain. An earth-boring tool includes a cutting element disposed at least partially within a pocket of a body. Methods of forming cutting elements comprise securing a generally planar volume of hard material to a body, attaching a sensor to the body, and configuring the sensor. Methods of forming earth-boring tools comprise forming a cutting element and securing the cutting element within a recess in a body of the earth-boring tool. Methods of forming wellbores comprise rotating an earth-boring tool comprising a cutting element and measuring at least one of stress and strain.

Abstract: In one aspect, a method of making a drill bit is disclosed that includes selecting a drill bit configuration, obtaining a stress map for the drill bit configuration relating to a drilling operation, performing a mechanical test with an actual drill bit having the selected configuration, and selecting a location on a surface of the drill bit for installing a sensor thereat based on a location of low stress from the stress map and results of the mechanical test, and placing a sensor at the selected location.

Abstract: A cutting element for an earth-boring tool includes a body having a longitudinal axis, a generally planar volume of hard material carried by the body, and a sensor affixed to the body. The sensor may be configured to sense at least one of stress and strain. An earth-boring tool includes a cutting element disposed at least partially within a pocket of a body. Methods of forming cutting elements comprise securing a generally planar volume of hard material to a body, attaching a sensor to the body, and configuring the sensor. Methods of forming earth-boring tools comprise forming a cutting element and securing the cutting element within a recess in a body of the earth-boring tool. Methods of forming wellbores comprise rotating an earth-boring tool comprising a cutting element and measuring at least one of stress and strain.

Abstract: A cutting element for an earth-boring tool includes an elongated body having a longitudinal axis, a generally planar volume of hard material attached to the elongated body, and a sensor affixed to the elongated body. The sensor may be configured to sense at least one of stress and strain. An earth-boring tool includes a cutting element disposed at least partially within a pocket of a body. Methods of forming cutting elements comprise securing a generally planar volume of hard material to an elongated body, attaching a sensor to the elongated body, and configuring the sensor. Methods of forming earth-boring tools comprise forming a cutting element and securing the cutting element within a recess in a body of the earth-boring tool. Methods of forming wellbores comprise rotating an earth-boring tool comprising a cutting element and measuring at least one of stress and strain.

Abstract: A method of forming an earth-boring tool includes introducing metal into a die, rotating the die to generate centrifugal forces on the metal, and cooling the metal in the rotating die. A rotary drill bit may include a unitary, centrifugally cast bit body including an integral shank, at least one blade, and at least one cutting element on the blade. A rotary drill bit or a roller cone may include a first centrifugally cast material and a second centrifugally cast material. Another rotary drill bit includes a bit body comprising a maraging steel alloy. A method of forming a rotary drill bit may include disposing cutting elements on a rotary drill bit comprising maraging steel and aging the rotary drill bit to form at least one intermetallic precipitate phase. Methods of repairing a rotary drill bit include annealing and aging at least a portion of a rotary drill bit.

Abstract: A drill pipe made according to one embodiment includes a number of serially connected tubulars with a communication device placed between the connecting ends of the tubulars, wherein the communication device provides a direct data communication link between the adjoining tubulars.

Abstract: A method of forming an earth-boring tool includes introducing metal into a die, rotating the die to generate centrifugal forces on the metal, and cooling the metal in the rotating die. A rotary drill bit may include a unitary, centrifugally cast bit body including an integral shank, at least one blade, and at least one cutting element on the blade. A rotary drill bit or a roller cone may include a first centrifugally cast material and a second centrifugally cast material. Another rotary drill bit includes a bit body comprising a maraging steel alloy. A method of forming a rotary drill bit may include disposing cutting elements on a rotary drill bit comprising maraging steel and aging the rotary drill bit to form at least one intermetallic precipitate phase. Methods of repairing a rotary drill bit include annealing and aging at least a portion of a rotary drill bit.

Abstract: A data acquisition module comprising a base sized and configured for disposition within a shank of a drill bit bore and an extension protruding therefrom having electrical contacts on an exterior surface thereof for connection to electrical contacts on an interior surface of a sub secured to the bit shank. A drill bit equipped with a data acquisition module, a bottom hole assembly including a drill bit bearing a data acquisition module operably coupled to a sub secured to the drill bit, and a method of transferring data from a data acquisition module carrying a data acquisition module to a sub secured to the drill bit.

Abstract: An apparatus and method of performing a wellbore operation. The apparatus includes a drill bit that has a cavity at an end thereof and a communication device placed in the cavity. The communication device includes a first section and a second section. An outer dimension of the second section is greater than an outer dimension of the first section. The second section includes a conduit configured to allow passage of a conductor from the drill bit to a location outside the drill bit so as to provide a direct connection of the conductor from the drill bit to an element outside the drill bit.

Abstract: In one aspect, an apparatus for use in a wellbore is provided that in one embodiment includes a drill bit having a bit body that is susceptible to corrosion when the drill bit is utilized in wellbore, an anode placed at a selected location on the bit body, a cathode associated with the bit body and a power source configured to provide electrical power to the anode to complete an electrical circuit between the anode and the bit body, wherein the supply of the electrical power to the anode arrests corrosion of the bit body when the drill bit is in the wellbore.

Abstract: Methods of attaching cutting elements to earth-boring tools, comprising abutting a portion of a cutting element against at least one surface of an earth-boring tool with a braze material disposed therebetween; and brazing the cutting element to the earth-boring tool by applying high-frequency vibrations to cause the braze material to become flowable. Methods of securing cutting elements to earth-boring tools may comprise at least partially coating a cutting element with a braze material. The cutting element may be at least partially disposed in a pocket formed in a body of an earth-boring tool with the braze material adjacent surfaces defining the pocket. The cutting element and the braze material may be ultrasonically torsionally oscillated to braze the cutting element within the pocket.

Abstract: A drill bit made according to one embodiment includes a source configured to induce radiation into a formation during drilling of a wellbore and a sensor in the drill bit configured to detect radiation from the formation responsive to the radiation induced by the source. The drill bit may further include a circuit configured to process signals received from the sensor to estimate a property of the formation.

Abstract: A drill bit made according to one embodiment may include a bit body having a longitudinal axis, a plurality of gamma sensors placed in the bit body, at least two gamma ray sensors in the plurality of sensors are spaced-apart from each other along the longitudinal axis of the bit body, wherein each such sensor in the plurality of sensors is configured to detect gamma rays from the formation during drilling of the wellbore and to provide signals representative of the detected gamma rays, and a circuit configured to process at least partially the signals from each of the at least two gamma ray sensors for estimating an inclination of the bit body relative to the longitudinal axis.

Abstract: Apparatuses and methods for adjusting weight-on-bit/torque-on-bit sensor bias in a drill bit. The apparatus may include a bit adjustment device disposed at least partially in a cavity in a bit shank. The bit adjustment device includes electronics and sensors for estimating a weight-on-bit/torque-on-bit bias. The method includes adjusting the weight-on-bit/torque-on-bit sensor bias of a drill bit. The method may include adjusting force on a bit adjustment device to adjust weight-on-bit/torque-on-bit sensor bias. The method may also include securing the bit adjustment device within the cavity of the bit shank after the desired weight-on-bit/torque-on-bit sensor bias has been achieved.

Abstract: In one aspect, the present disclosure provides an apparatus for determining formation density. One embodiment of the apparatus includes a bottomhole assembly having a drill bit attached to end thereof for drilling through a formation, a first sensor in the drill bit configured to provide first signals for determining a first density of the formation proximate to the drill, a second sensor distal from the first sensor configured to provide signals for determining density of a second density of the formation, and a processor configured to determine the formation density from the first density and the second density.

Abstract: A method of forming an earth-boring tool includes introducing metal into a die, rotating the die to generate centrifugal forces on the metal, and cooling the metal in the rotating die. A rotary drill bit may include a unitary, centrifugally cast bit body including an integral shank, at least one blade, and at least one cutting element on the blade. A rotary drill bit or a roller cone may include a first centrifugally cast material and a second centrifugally cast material. Another rotary drill bit includes a bit body comprising a maraging steel alloy. A method of forming a rotary drill bit may include disposing cutting elements on a rotary drill bit comprising maraging steel and aging the rotary drill bit to form at least one intermetallic precipitate phase. Methods of repairing a rotary drill bit include annealing and aging at least a portion of a rotary drill bit.

Abstract: Methods of attaching cutting elements to earth-boring tools, comprising abutting a portion a cutting element against at least one surface of an earth-boring tool with a braze material disposed therebetween; and brazing the cutting element to the earth-boring tool by applying high-frequency vibrations to cause the braze material to become flowable. Methods of securing cutting elements to earth-boring tools may comprise at least partially coating a cutting element with a braze material. The cutting element may be at least partially disposed in a pocket formed in a body of an earth-boring tool with the braze material adjacent surfaces defining the pocket. The cutting element and the braze material may be ultrasonically torsionally oscillated to braze the cutting element within the pocket.

Abstract: A data acquisition module comprising a base sized and configured for disposition within a shank of a drill bit bore and an extension protruding therefrom having electrical contacts on an exterior surface thereof for connection to electrical contacts on an interior surface of a sub secured to the bit shank. A drill bit equipped with a data acquisition module, a bottom hole assembly including a drill bit bearing a data acquisition module operably coupled to a sub secured to the drill bit, and a method of transferring data from a data acquisition module carrying a data acquisition module to a sub secured to the drill bit.