Earth-boring tools for coupling to casings and related systems and methods

Abstract

A downhole tool assembly for use in a wellbore includes a first casing section configured to be inserted into a borehole, a second casing section configured to be inserted into the borehole, and an earth-boring tool comprising at least one blade coupled between the first casing section and the second casing section. The at least one blade is configured to remove material from a downhole formation.

What is claimed is: 
     
         1 . A downhole tool assembly, comprising:
 a first casing section configured to be inserted into a borehole;   a second casing section configured to be inserted into the borehole; and   an earth-boring tool comprising at least one blade located between the first casing section and the second casing section;   wherein the at least one blade comprises one or more cutting elements and is configured to remove material from a downhole formation.   
     
     
         2 . The downhole tool assembly of  claim 1 , wherein the at least one blade comprises a gauge section defining an outside diameter of the earth-boring tool. 
     
     
         3 . The downhole tool assembly of  claim 2 , wherein the outside diameter of the earth-boring tool is between 100% and 150% of an outside diameter of at least one of the first casing section and the second casing section. 
     
     
         4 . The downhole tool assembly of  claim 3 , wherein the outside diameter of the earth-boring tool is less than an inside diameter of the borehole. 
     
     
         5 . The downhole tool assembly of  claim 1 , wherein the first casing section is coupled to a casing bit at an end of the first casing section opposite the earth-boring tool. 
     
     
         6 . The downhole tool assembly of  claim 1 , wherein the earth-boring tool comprises a coupler configured to couple the first casing section to the second casing section. 
     
     
         7 . The downhole tool assembly of  claim 1 , wherein the one or more cutting elements comprise polycrystalline diamond cutting elements. 
     
     
         8 . The downhole tool assembly of  claim 1 , wherein the at least one blade comprises hardfacing. 
     
     
         9 . The downhole tool assembly of  claim 1 , further comprising a third casing section and a second earth-boring tool located between the second casing section and the third casing section. 
     
     
         10 . The downhole tool assembly of  claim 9 , further comprising at least four earth-boring tools, wherein each of the at least four earth-boring tools are coupled between different casing sections along a casing string. 
     
     
         11 . The downhole tool assembly of  claim 1 , wherein the earth-boring tool is coupled to at least one of the first casing section and the second casing section with a threaded connection. 
     
     
         12 . The downhole tool assembly of  claim 11 , wherein the threaded connection further comprises a weld. 
     
     
         13 . A method of securing a casing string in an earth formation comprising:
 inserting a casing string into an earth formation;   rotating the casing string;   removing an obstruction in a wellbore with an earth-boring tool coupled between at least two segments of casing in the casing string by rotation of the casing string; and   securing the casing string and the earth-boring tool in place within the wellbore.   
     
     
         14 . The method of  claim 13 , further comprising drilling the wellbore with a casing shoe coupled to a first segment of casing in the casing string. 
     
     
         15 . The method of  claim 13 , wherein inserting the casing string into the formation comprises inserting the casing string into an already drilled wellbore. 
     
     
         16 . The method of  claim 13 , wherein securing the casing string and the earth-boring tool comprises providing zonal isolation for the casing string with cement. 
     
     
         17 . The method of  claim 13 , wherein securing the casing string and the earth-boring tool further comprises flowing cement between junk slots of the earth-boring tool. 
     
     
         18 . A method of manufacturing an earth-boring tool comprising:
 forming a body of the earth-boring tool comprising:
 at least one blade extending radially from the body; 
 a bore extending through the body along a longitudinal axis of the body; and 
 threads on both a first end of the body and a second end of the body, wherein the threads are configured to couple the body between segments of casing in a casing string. 
   
     
     
         19 . The method of  claim 18 , further comprising forming pockets on the at least one blade. 
     
     
         20 . The method of  claim 19 , further comprising securing cutting elements within the pockets on the at least one blade.