Originally Posted by tomjohn777
Two pieces of metal welded together "properly" are stronger than the steel is on it's own. BUT that means a full penetration weld without defects,I don't know how your welding skills are, But if you can weld I would say go for it! It will probably be plenty strong enough and you can say that you made it yourself.
That also means post-weld heat-treatment (to reduce the effects of the change in temper at the borders of the HAZ...)
Given a choice, I'll make forms to bend the metal around, then heat up the whole piece of metal and bend it. Fewer discontinuities, no HAZ, and simpler heat-treatment (since you just have to worry about work hardening instead of the HAZ and discontinuities.)
The HAZ decreases as the process advances - torch>stick>MIG>TIG - but you can't get away from it.
Mounts are bent because it is easier and cheaper to do so, just as screw threads are rolled because it is easier and cheaper to do so. This is a case where doing something the easy way gets you a better part (rolled threads are effectively cold-forged and the material compressed, while a cut thread is effectively a stress riser in the material.) In softer materials, you should use a thread forming
tap instead of a thread cutting
tape - same reasons.