Round vs square

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nvn
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hydro joe: For a 38.1 x 2.413 mm round tube, versus a 38.1 x 2.413 mm square tube, the square tube plastic bending strength, in an orthogonal direction, is 1.50 times the plastic bending strength of the above round tube. In the 45 deg direction, the square tube plastic bending strength is 1.4142 times the plastic bending strength of the above round tube.

Regarding question 2 in post 1, welding generally weakens steel. Even though the weld metal is often stronger, the base metal generally becomes weaker in the heat-affected zone.
 
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