Abstract: Methods of forming earth-boring tools include using a plasma spray device to gouge at least one recess through a hardfacing material and into a body. At least a portion of the recess may define a cutting element pocket in which a cutting element may be received and bonded. The recess formed using the plasma spray device optionally may be further machined to form the cutting element pocket. Earth-boring tools are fabricated using such methods.

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: Methods of forming earth-boring tools include using a plasma spray device to gouge at least one recess through a hardfacing material and into a body. At least a portion of the recess may define a cutting element pocket in which a cutting element may be received and bonded. The recess formed using the plasma spray device optionally may be further machined to form the cutting element pocket. Earth-boring tools are fabricated using such methods.

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: Methods of forming earth-boring tools include using a plasma spray device to gouge at least one recess through a hardfacing material and into a body. At least a portion of the recess may define a cutting element pocket in which a cutting element may be received and bonded. The recess formed using the plasma spray device optionally may be further machined to form the cutting element pocket. Earth-boring tools are fabricated using such methods.

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: Components, such as a cutting element for an earth-boring drilling tool, include an ultrasonic transducer coupled therewith and configured to transmit an acoustic signal therethrough, and transmit a data signal to a data acquisition unit in response to receiving a returning echo of the acoustic signal. An earth-boring drilling tool comprises a bit body including a plurality of components, an ultrasonic transducer, and a data acquisition unit operably coupled with the ultrasonic transducer. The data acquisition unit may be configured to receive the data signal and determine a temperature distribution of the component based, at least in part, on a time-of-flight of the acoustic signal and the returning echoes. Methods for forming such components and measuring a temperature of such components may relate to coupling and implementing such an ultrasonic transducer with a component of an earth-boring drilling tool.

Abstract: Components, such as a cutting element for an earth-boring drilling tool include an ultrasonic transducer coupled therewith, and configured to transmit an acoustic signal therethrough, and transmit a data signal to a data acquisition unit in response to receiving a returning echo of the acoustic signals. An earth-boring drilling tool, comprises a bit body including a plurality of components, an ultrasonic transducer, and a data acquisition unit operably coupled with the ultrasonic transducer. The data acquisition unit may be configured to receive the data signal and determine a temperature distribution of the component based, at least in part, on a time-of-flight of the acoustic signals and the returning echoes. Methods for forming such components and measuring a temperature of such components may relate to coupling and implementing such an ultrasonic transducer with a component of an earth-boring drilling tool.

Abstract: Methods of forming earth-boring tools include using a plasma spray device to gouge at least one recess through a hardfacing material and into a body. At least a portion of the recess may define a cutting element pocket in which a cutting element may be received and bonded. The recess formed using the plasma spray device optionally may be further machined to form the cutting element pocket. Earth-boring tools are fabricated using such methods.

Abstract: Components, such as a cutting element for an earth-boring drilling tool include an ultrasonic transducer coupled therewith, and configured to transmit an acoustic signal therethrough, and transmit a data signal to a data acquisition unit in response to receiving a returning echo of the acoustic signals. An earth-boring drilling tool, comprises a bit body including a plurality of components, an ultrasonic transducer, and a data acquisition unit operably coupled with the ultrasonic transducer. The data acquisition unit may be configured to receive the data signal and determine a temperature distribution of the component based, at least in part, on a time-of-flight of the acoustic signals and the returning echoes. Methods for forming such components and measuring a temperature of such components may relate to coupling and implementing such an ultrasonic transducer with a component of an earth-boring drilling tool.

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: 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: Components, such as a cutting element for an earth-boring drilling tool include an ultrasonic transducer coupled therewith, and configured to transmit an acoustic signal therethrough, and transmit a data signal to a data acquisition unit in response to receiving a returning echo of the acoustic signals. An earth-boring drilling tool, comprises a bit body including a plurality of components, an ultrasonic transducer, and a data acquisition unit operably coupled with the ultrasonic transducer. The data acquisition unit may be configured to receive the data signal and determine a temperature distribution of the component based, at least in part, on a time-of-flight of the acoustic signals and the returning echoes. Methods for forming such components and measuring a temperature of such components may relate to coupling and implementing such an ultrasonic transducer with a component of an earth-boring drilling tool.

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.