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 method of improving the service life of a drill bit comprises creating a weldment between load bearing portions of the drill bit where the weldment has a preselected root gap greater than about 25 mils and a preselected root face greater than about 25 mils, and where the weldment has a material property greater than the materials being joined.

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: 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: 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: Methods and associated tools and components related to generating and obtaining performance data during drilling operations of a subterranean formation is disclosed. Performance data may include thermal and mechanical information related to earth-boring drilling tool during a drilling operation are disclosed. For example, a cutting element of an earth-boring drilling tool may include a substrate with a cutting surface thereon. The cutting element may further include at least one thermistor sensor coupled with the cutting surface, and a conductive pathway operably coupled with the at least one thermistor sensor. The at least one thermistor sensor may be configured to vary a resistance in response to a change in temperature. The conductive pathway may be configured to provide a current path through the at least one thermistor sensor in response to a voltage. Other methods, tools and components are provided.

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.

Abstract: In one aspect, a removable module or sub is provided for use in drilling a wellbore, which sub in one embodiment may include a body having a pin end and a box end configured for coupling between two members of a drill string, the body having a bore therethrough for flow of a fluid, and a sensor disposed in a pressure-sealed chamber in one of the pin end and the box end and configured to provide measurements relating to a downhole condition.

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: Casing shoes comprise a nose portion having an inner profile and an outer profile. At least one cutting structure is on the outer profile. A stem section extends longitudinally from the nose portion. At least one of a float valve mechanism, a cementing stage tool, a float collar mechanism, and a landing collar structure is disposed within the stem section. Methods of installing sections of casing within wellbores comprise advancing the at least one section of casing into contact with subterranean formation material with a casing shoe attached thereto. At least one of a float valve mechanism, a cementing stage tool, a float collar mechanism, and a landing collar structure is carried within the casing shoe into the wellbore. The wellbore is drilled or reamed using at least one cutting structure on the casing shoe as the at least one section of casing is advanced into the wellbore.

Abstract: A rock bit is formed with pockets for enhanced cutting element retention and support of cutting elements during operation of the rock bit. Portions of the pockets are carburized to increase a yield strength of the pockets, which also increases the retention of the cutting elements. The pockets are formed at a diameter that is slightly smaller than an outer diameter of the cutting elements. Portions of the pockets are then carburized. The pockets are heated until the diameter of the pockets is equal to the outer diameter of the cutting elements. After the rock bit has been cooled and cleaned, a material is placed in each pocket prior to installing the cutting elements. The material homogenizes support for the cutting elements during operation of the rock bit.

Abstract: A casing bit, which may comprise a composite structure, for drilling a casing section into a subterranean formation, and which may include a portion configured to be drilled therethrough. Cutting elements and methods of use may be included. Adhesive, solder, electrically disbonding material, and braze affixation of a cutting element may be included. Differing abrasive material amount, characteristics, and size of cutting elements may be included. Telescoping casing sections and bits may be included. Embodiments may include: at least one gage section extending from the nose portion, at least one rotationally trailing groove formed in at least one of the plurality of blades, a movable blade, a leading face comprising superabrasive material, at least one of a drilling fluid nozzle and a sleeve, grooves for preferential failure, at least one rolling cone affixed to the nose portion, at least one sensor, discrete cutting element retention structures, and percussion inserts.

Abstract: A casing bit, which may comprise a composite structure, for drilling a casing section into a subterranean formation, and which may include a portion configured to be drilled therethrough. Cutting elements and methods of use may be included. Adhesive, solder, electrically disbonding material, and braze affixation of a cutting element may be included. Differing abrasive material amount, characteristics, and size of cutting elements may be included. Telescoping casing sections and bits may be included. Embodiments may include: at least one gage section extending from the nose portion, at least one rotationally trailing groove formed in at least one of the plurality of blades, a movable blade, a leading face comprising superabrasive material, at least one of a drilling fluid nozzle and a sleeve, grooves for preferential failure, at least one rolling cone affixed to the nose portion, at least one sensor, discrete cutting element retention structures, and percussion inserts.

Abstract: A casing bit, which may comprise a composite structure, for drilling a casing section into a subterranean formation, and which may include a portion configured to be drilled therethrough. Cutting elements and methods of use may be included. Adhesive, solder, electrically disbonding material, and braze affixation of a cutting element may be included. Differing abrasive material amount, characteristics, and size of cutting elements may be included. Telescoping casing sections and bits may be included. Embodiments may include: at least one gage section extending from the nose portion, at least one rotationally trailing groove formed in at least one of the plurality of blades, a movable blade, a leading face comprising superabrasive material, at least one of a drilling fluid nozzle and a sleeve, grooves for preferential failure, at least one rolling cone affixed to the nose portion, at least one sensor, discrete cutting element retention structures, and percussion inserts.

Abstract: A casing bit, which may comprise a composite structure, for drilling a casing section into a subterranean formation, and which may include a portion configured to be drilled therethrough, is disclosed. Cutting elements and methods of use are disclosed. Adhesive, solder, electrically disbonding material, and braze affixation of a cutting element are disclosed. Differing abrasive material amount, characteristics, and size of cutting elements are disclosed. Telescoping casing sections and bits are disclosed. Aspects and embodiments are disclosed including: at least one gage section extending from a nose portion, at least one rotationally trailing groove formed in at least one of a plurality of blades, a movable blade, a leading face comprising superabrasive material, at least one of a drilling fluid nozzle and a sleeve, grooves for preferential failure, at least one rolling cone affixed to the nose portion, at least one sensor, discrete cutting element retention structures, and percussion inserts.

Abstract: A drill string component includes a box-end and a pin-end. Each end includes a signal transceiver, which are operably coupled together. Each signal transceiver communicates with another signal transceiver in another component to form a communication network in the drillstring. An end-cap may be placed in the central bore of the pin-end of a component to form an annular chamber between a side of the end-cap and a wall of the central bore of the pin-end when the end-cap is disposed in the central bore. In some embodiments, an electronics module may be placed in the annular chamber and configured to communicate with one of the signal transceivers. Accelerometer data, as well as other sensor data, at various locations along the drillstring may be sampled by the electronics module and communicated to a remote computer. Drillstring motion dynamics, such as vibration, may be determined based on the accelerometer data.

Abstract: Drill bits and methods for sampling sensor data associated with a state of a drill bit are disclosed. A drill bit for drilling a subterranean formation comprises a bit configured for receiving a data analysis module. The data analysis module comprises at least one sensor, a memory, and a processor. The processor is configured for executing computer instructions to filter information derived from sensor data in the drill bit to develop a piecewise polynomial curve of the sensor data. Filtering information derived from the sensor data comprises approximating a first derivative of a sensor data waveform, calculating a plurality of zeros for the first derivative of the sensor data waveform, and fitting a cubic polynomial between adjacent zeros calculated from the first derivative of the sensor data waveform resulting in a piecewise cubic polynomial.