Abstract: Cutters for a downhole drill bit can be formed by providing a catalyst-free synthesized polycrystalline diamond (PCD) having a cross-sectional dimension of at least 8 millimeters; providing a substrate comprising tungsten carbide; and attaching the synthesized PCD to the substrate comprising tungsten carbide to form a PDC cutter.

Abstract: Systems and methods include a computer-implemented method can be used to make drilling tools from new wurtzite boron nitride (w-BN) superhard material. An ultra-high-pressure, high-temperature operation is performed on pure w-BN powder to synthesize w-BN and cubic boron nitride (c-BN) compact having a first size greater than particles of the pure w-BN powder. The ultra-high-pressure, high-temperature operation includes pressurizing the w-BN powder to a pressure of approximately 20 Gigapascal, heating the w-BN powder at a heating rate of 100° C./minute and cooling the w-BN powder at a cooling rate of 50° C./minute. The compact is cut to a second size smaller than the first size using laser cutting tools. The cut compact is bonded metallurgically, mechanically, or both metallurgically and mechanically onto a tool substrate to form the drilling tool.

Abstract: Tools and methods are described to measure dimensions of wellbores. Downhole caliper tools include a downhole collar and an uphole collar having a running position and a sensing position. The uphole collar is farther from the downhole collar in the running position than in the sensing position. A caliper sensor assembly includes: a sensor module defining tracks extending parallel to an axis of the caliper tool, the sensor module positioned towards an uphole end of the caliper tool relative to the uphole collar; and a caliper disposed between the downhole collar and the uphole collar including: a flexible mesh extending from the downhole collar to the uphole collar. Movement of the uphole collar from the running position to the sensing position axially compresses and radially expands the flexible mesh. The annular sensor module can measure dimensions of the flexible mesh relative to the axis of the caliper tool.

Abstract: A system and a method for forming a composite electrolyte structure are provided. An exemplary composite electrolyte structure includes, at least in part, polymer electrolyte preforms that are bonded into the composite electrolyte structure.

Abstract: An example system for operation in a borehole in a hydrocarbon-bearing rock formation includes a logging tool for detecting one or more conditions in the borehole. The logging tool includes a tool body and a 4D printed sensing element. The 4D printed sensing element includes a 3D printed shape-memory material configured to alter in at least one spatial dimension in response to one or more stimuli, thereby generating a data signal. The example system includes a data recording device in communication with the logging tool to receive and record one or more data signals transmitted from the logging tool.

Abstract: Systems and methods for managing a loss circulation zone in a subterranean well include a tool housing located on a surface of a tubular member with a tool cavity that is an interior open space within the tool housing. An electromechanical system is located within the tool cavity and has a printed circuit board, a microprocessor, a sensor system, a power source, and a communication port assembly. A release system can move a deployment door of a deployment opening of the tool housing between a closed position and an open position. The deployment opening can provide a flow path between the tool cavity and an outside of the tool housing. The release system is actuable autonomously by the electromechanical system. A releasable product is located within the tool cavity and can travel through the deployment opening when the deployment door is in the open position.

Abstract: A wellbore fluid monitoring system includes a housing, an air flow sensor, a first sealing element, a second sealing element and a sealing unit. The housing is configured to be securely disposed in a portion of an annulus within a bell nipple below a rotary table of a wellbore drilling assembly. The annulus is formed by a drill string of the wellbore drilling assembly and an inner wall of a wellbore being drilled by the wellbore drilling assembly. The housing includes a hollow internal chamber. The air flow sensor is disposed within the hollow internal chamber. The air flow sensor is configured to sense flow of air through the hollow internal chamber. The first sealing element is attached to a first end of the housing. The second sealing element is attached to a second end of the housing. The sealing unit is disposed in the portion of the annulus. The sealing unit is connected to the housing, the first sealing element and the second sealing element.

Abstract: A wellbore fluid monitoring system can implement a method while drilling a wellbore using a drilling assembly that includes a drill string, a rotary table and a bell nipple below the rotary table. Air flowing in a downhole direction through a portion of an annulus within the bell nipple below the rotary table responsive to a decrease in a liquid level in the portion of the annulus is sensed. The annulus is formed by the drill string and an inner wall of the wellbore. In response to sensing the air flowing in the downhole direction, a flow rate of the air flowing in the downhole direction over a period of time is measured. Based on the flow rate and the period of time, a volume of air flowed in the downhole direction over the period of time is determined. A liquid level relative to the rotary table is determined based on the volume of air flowed in the downhole direction over the period of time.

Abstract: A wellbore fluid monitoring system includes a housing, a first sealing element, a second sealing element and a sealing unit. The housing is configured to be securely disposed in a portion of an annulus within a bell nipple below a rotary table of a wellbore drilling assembly. The annulus is formed by a drill string of the wellbore drilling assembly and an inner wall of a wellbore being drilled by the wellbore drilling assembly. The housing includes a first open end and a second open end. The housing is configured to house an air flow sensor disposed within the housing. The first sealing element is attached to the first open end of the housing. The first sealing element is configured to seal and unseal the first open end. The second sealing element is attached to the second open end of the housing. The second sealing element is configured to seal and unseal the second open end. The sealing unit is disposed in the portion of the annulus.

Abstract: A wellbore fluid monitoring system includes a housing, an air flow sensor, a first sealing element, a second sealing element and a sealing unit. The housing is configured to be securely disposed in a portion of an annulus within a bell nipple below a rotary table of a wellbore drilling assembly. The annulus is formed by a drill string of the wellbore drilling assembly and an inner wall of a wellbore being drilled by the wellbore drilling assembly. The housing includes a hollow internal chamber. The air flow sensor is disposed within the hollow internal chamber. The air flow sensor is configured to sense flow of air through the hollow internal chamber. The first sealing element is attached to a first end of the housing. The second sealing element is attached to a second end of the housing. The sealing unit is disposed in the portion of the annulus. The sealing unit is connected to the housing, the first sealing element and the second sealing element.

Abstract: The present disclosure is directed to systems, methods, and apparatuses for obtaining sensor data from sensors incorporated into a drill bit during a drilling operation to form a wellbore. The obtained sensor data may be used to control an aspect of the drilling operation. The sensors may be incorporated into drill bit cutters of a drill bit, a drill bit body of a drill bit, or both. Example sensors include acoustic sensors, pressure sensor, vibration sensor, accelerometers, gyroscopic sensors, magnetometer sensors, and temperature sensors.

Abstract: Methods and systems for monitoring conditions within a wellbore of a subterranean well include extending a drill string into the subterranean well from a terranean surface. The drill string has an actuator assembly, a sensor compartment, and a plurality of sensors located within the sensor compartment. The actuator assembly is instructed to transmit a swarm release signal to a central power unit of the sensor compartment so that the central power unit of the sensor compartment releases certain of the plurality of sensors from the sensor compartment. Data from the sensors is transferred to a data processing system after the sensors reach the terranean surface.

Abstract: A drill bit includes multiple cutting devices and a microelectronics unit. Each cutting device of the multiple cutting devices includes a cutting layer formed to cut a rock formation and a capacitive sensor disposed adjacent the cutting layer. The capacitive sensor is configured to generate an electric field across the cutting layer and to transmit a signal corresponding to a voltage associated with the electric field. The microelectronics unit of the drill bit is configured to receive the signal from the capacitive sensor of each cutting device of the multiple cutting devices such that the microelectronics unit receives multiple signals and to determine an indicator of mechanical wear of the drill bit based on a change in the voltage associated with the electric field across the cutting layer of each cutting device of the multiple cutting devices using the multiple signals.

Abstract: A microchip includes a PCB, a first contact feature positioned along a first area of the PCB, a second contact feature positioned along a second area of the PCB that is disposed opposite the first area, a contact frame including first and second contact members respectively coupled to the first and second contact features for signal communication between the first and second contact features and an external electronic device, and a housing enclosing an interior region of the microchip and carrying the first and second contact members of the contact frame.

Abstract: Systems and methods include a computer-implemented method can be used to make milling tools from new wurtzite boron nitride (w-BN) superhard material. An ultra-high-pressure, high-temperature operation is performed on pure w-BN powder to synthesize w-BN and cubic boron nitride (c-BN) compact having a first size greater than particles of the pure w-BN powder. The ultra-high-pressure, high-temperature operation includes pressurizing the w-BN powder to a pressure of approximately 20 Gigapascal, heating the w-BN powder at a heating rate of 100° C./minute and cooling the w-BN powder at a cooling rate of 50° C./minute. The compact is cut to a second size smaller than the first size using laser cutting tools. The cut compact is turbulently mixed with additives in a mixer under vacuum. The cut compact mixed with the additives is thermally sprayed onto a tool substrate to form the tool.

Abstract: Systems and methods include a computer-implemented method for manufacturing a binder for spraying onto tools. A binder is manufactured for binding compacts onto a tool substrate. The binder is designed to provide a coating strength on the tool substrate. The binder includes: a metal selected from iron (Fe), cobalt (Co), and nickel (Ni); an alloy including the metal selected from Fe, Co, and Ni; or a refractory alloy selected from tungsten, tantalum (Ta), molybdenum (Mo), and niobium (Nb). An ultra-high-pressure, high-temperature operation is performed on pure wurtzite boron nitride (w-BN) powder to synthesize w-BN and cubic boron nitride (c-BN) compact. A binder-compact mixture is produced by turbulently mixing the binder with the compact in a mixer within a vacuum. The binder-compact mixture is thermally sprayed onto a tool substrate to coat the tool.

Abstract: The present disclosure is directed to systems, methods, and apparatuses for obtaining sensor data from sensors incorporated into a drill bit during a drilling operation to form a wellbore. The obtained sensor data may be used to control an aspect of the drilling operation. The sensors may be incorporated into drill bit cutters of a drill bit, a drill bit body of a drill bit, or both. Example sensors include acoustic sensors, pressure sensor, vibration sensor, accelerometers, gyroscopic sensors, magnetometer sensors, and temperature sensors.

Abstract: A drill bit includes multiple cutting devices and a microelectronics unit. Each cutting device of the multiple cutting devices includes a cutting layer formed to cut a rock formation and a capacitive sensor disposed adjacent the cutting layer. The capacitive sensor is configured to generate an electric field across the cutting layer and to transmit a signal corresponding to a voltage associated with the electric field. The microelectronics unit of the drill bit is configured to receive the signal from the capacitive sensor of each cutting device of the multiple cutting devices such that the microelectronics unit receives multiple signals and to determine an indicator of mechanical wear of the drill bit based on a change in the voltage associated with the electric field across the cutting layer of each cutting device of the multiple cutting devices using the multiple signals.

Abstract: A casing for a drilling operation has a body portion having a length, a first end and a second end, an outer diameter, an inner diameter, and a central axis that is common to the outer diameter and the inner diameter, and an external thread formed on the outer diameter of the body portion, wherein the external thread starts at a first predetermined distance from the first end and ends at a second predetermined distance from the second end. The external thread includes a spiral groove or a helical thread formed on the outer diameter of the body portion. The casing includes a coating at least partially encapsulating the external thread, wherein the coating includes at least one material selected from the group consisting of polycrystalline diamond particles, diamond like carbon (DLC), tungsten carbide, boron nitride, silicon carbide, silicon nitride, and combinations thereof.

Abstract: Methods, systems, and apparatus for carrying out rapid on-site optical chemical analysis in oil feeds are described. In one aspect, a system for manufacture of a tool includes a deposition reactor configured for molecular layer deposition or atomic layer deposition of metal powder to manufacture coated particles, a fabrication unit configured for 3D printing of the tool, and a controller that controls the deposition reactor and the fabrication unit, wherein the fabrication unit and the deposition reactor are integrated for automated fabrication of the tool using the coated particles from the deposition reactor as building material for the 3D printing.