Here is a little more material on round vs square tube...found on
www.auf.asn.au/scratchbuilder/metals.htmlEffect of shape on stiffness
Structural stiffness in bending or torsion is as important as strength; for example if the aft fuselage bends under changing aerodynamic loads on the tailplane surfaces the angle of attack of those surfaces will change, thus again changing the load ... and so the cycle continues. In the turbulent atmospheric conditions often encountered near the surface lack of structural stiffness substantially increases pilot work load and adds to airframe fatigue — see below.
The modulus of elasticity expresses the stiffness value of standard test pieces but stiffness of formed metal is also dependent on the geometry of the material. For example the stiffness of a solid metal bar of particular cross-section area can be substantially changed by reforming it as an angle section, channel section, 'T' section, 'I' section or a round, rectangular or streamlined tube, of the same length and mass. An aircraft designer will be looking for the most efficient material shape for each structural element i.e. the shape that provides the required stiffness and strength with the least weight.
Structural elements loaded only in tension or compression are, except for long columns, generally very stiff and that stiffness is dependent on the cross-section area [as is the strength] not the cross-section shape. However the resistance to bending and torsion loads [which are combinations of tension and compression stress acting opposite to each other] is allied to the shape of the element; for example:
Round or rectangular tubes and other enclosed shapes resist torsion well and are more rigid against torsion than an 'I' section.
An 'I' section resists bending better than round or rectangular tubes and that bending stiffness is proportional to the section depth cubed: see properties of beams.
A hollow circular shaft is the most efficient shape for carrying a torque — hence torque tubes.
a round tube has the greatest resistance to buckling in compression — and tubing trusses nearly always fail in compression by buckling, see long column buckling below.
The bending and torsional stiffness of a tube is a function of diameter and wall thickness. If a round tube of particular outside diameter is reformed into a larger diameter tube of the same length but reduced wall thickness the wider tube will be stiffer than the original tube even though the mass is the same. (The increase in stiffness is in proportion to the square of the diameter.) Or a round aluminium tube of 50 mm outside diameter and 2 mm wall thickness will be eight times stiffer than a tube half its diameter with the same wall thickness, even though the larger tube has only slightly more than twice the mass. (The increase in stiffness is in proportion to the cube of the diameter if the wall thickness is maintained — or if the wall thickness is doubled the bending stiffness is also doubled.)
However as you might imagine there is a limiting relationship between outside diameter and wall thickness before buckling potential might become a problem; also very thin walled steel tubing is difficult to weld so there is a minimum wall thickness associated with welded tube structures.
Round rather than square metal tubing is the material of structural choice because a given mass of metal can be formed into a larger diameter [and thus stiffer] tube of the same wall thickness and length if round rather than square. The mass of metal contained in a 10 mm × 10 mm × 2 mm wall thickness square tube would produce a 12 mm outside diameter × 2 mm wall thickness round tube of the same length, which would be considerably stiffer and more resistant to long column buckling. Conversely a round tube can provide the same stiffness as a square tube but with considerably less weight.
However square steel tube greatly simplifies welded truss fabrication as parts can be mated with simple straight angled cuts whereas round tube requires more complex radius cutting [a fish mouth] to properly mate the parts prior to welding. This advantage may be appealing to someone who is prepared to trade the long term weight penalty [for example reduction in payload and rate of climb, increase in fuel bills] for the short time saved in construction. Round tubing is the primary material in most factory built steel truss fuselages. There may be advantages in using square tubing for fuselage longerons and round tubing for the other members.
To cut a long story short..... ROUND is stronger than SQUARE as Landyacht main spine