I'd like to solve the integral
$$I := \int_{0}^{\pi/2} \ln(\sec^{2}(x) + \tan^{4}(x)) \mathrm{d}x$$
using the method of differentiating under the integral sign. So, first substituting $\tan x=u$, we get $\sec^2x \mathrm{d}x = \mathrm{d}u$, meaning $\mathrm{d}x = \frac{\mathrm{d}u}{\sec^2(\tan^{-1} u)} = \frac{\mathrm{d}u}{1+u^2}$. So, we have
$$I = \int_{0}^{\infty} \ln(1+u^{2} + u^{4}) \frac{\mathrm{d}u}{1+u^2}.$$
Let's define $I(t)$ as
$$I(t) := \int_{0}^{\infty} \ln(1+t[u^{2} + u^{4}]) \frac{\mathrm{d}u}{1+u^2},$$
where $I(t=0) = 0$. Then, differentiating w.r.t. $t$ yields
$$I'(t) = \int_{0}^{\infty} \frac{[u^{2} + u^{4}]\mathrm{d}u}{(1+t[u^{2} + u^{4}])(1+u^2)} = \int_{0}^{\infty} \frac{u^{2}\mathrm{d}u}{1+tu^{2}(1 + u^{2})}.$$
Let $x = u^2$. Then, $\mathrm{d}u = \frac{\mathrm{d}x}{2\sqrt{x}}$, leading to
$$I'(t) = \frac{1}{2t}\int_{0}^{\infty} \frac{\sqrt{x}\mathrm{d}x}{(x+\frac{1}{2})^2 + (\frac{1}{t}-\frac{1}{4})}.$$
Does this integral even converge? If so, how can one evaluate it? If otherwise, what have I done wrong here?
Continuing from your derivative step, instead by symmetry we have
$$I'[t] = \frac{1}{2}\int_{-\infty}^\infty \frac{u^2\:du}{1+tu^2+tu^4} = \frac{1}{2}\int_{-\infty}^\infty \frac{du}{t+2\sqrt{t}+t\left(u-\frac{1}{u\sqrt{t}}\right)^2}$$
We can now use Glasser's Master theorem to state that $\int_{-\infty}^\infty f\left(x-\frac{a}{x}\right)dx = \int_{-\infty}^\infty f(x)dx$ for positive $a$
$$I'[t] = \frac{1}{2t}\int_{-\infty}^\infty\frac{du}{\left(1+\frac{2}{\sqrt{t}}\right)+u^2} = \frac{\pi}{2t\sqrt{1+\frac{2}{\sqrt{t}}}}$$
Integrating, this suggests using the substitution $s = \sqrt{1+\frac{2}{\sqrt{t}}}$, which gives
$$I[t] = \int \frac{2\pi \:ds}{1-s^2} = 2\pi\coth^{-1}s+C = 2\pi\coth^{-1}\sqrt{1+\frac{2}{\sqrt{t}}}+C$$
being cognizant of using the appropriate branch between $\tanh^{-1}$ and $\coth^{-1}$. To find $C$, note that
$$I[0] = 0 = 2\pi\coth^{-1}(\infty)+C = 0 + C$$
$$\implies \boxed{I[t] = 2\pi\coth^{-1}\sqrt{1+\frac{2}{\sqrt{t}}}}$$
And the integral we want is $I[1]$
$$I[1] = \boxed{2\pi\coth^{-1}\sqrt{3}}$$
EDIT: Just for fun, we can simplify the $I[t]$ formula using hyperbolic identities
$$I[t] = 2\pi\coth^{-1}\sqrt{1+\frac{2}{\sqrt{t}}} = 2\pi\sinh^{-1}\sqrt[4]{\frac{t}{4}} = \pi \cosh^{-1}\left(1+\sqrt{t}\right)$$
from $\coth^2\tau - 1 = \frac{1}{\sinh^2\tau}$ first and then $\cosh2\tau = 1+2\sinh^2\tau$ second.