The difference isn't that significant if it is late in the combo, for instance after 3d2, f23, f23.
I don't use the sword in my corner combos unless I'm trying to wall-bounce my opponent and get them away from the corner with b13. My bnb corner combo is 3d2, f23, f23, f12.
Point is though, d2~d4 is the only sure way to hit the rising sword in the corner.
3d2, f23, f23, d2~d4, 112 does 44% compared to 3d2, f23, f23, 112~d4, 112 which does 52%
3d2, f23, f23, 112~de actually does 45%, so there's literally no damage to be gained by using the d2~sword in that combo. It's only good for a set up, like you mentioned
I agree with you about not using the sword in the corner, though. Ares gets pretty solid meterless corner damage even without using the sword to extend it. I usually just hold on to my sword and save it as a launcher.
Damage scales horribly on D2's compared to 2,2, B1, or 1,1,2. Another thing I haven't added yet is with 2,2/D4, the sword whiffs. I think this also applies with B1 and maybe 1,1,2 as far as launching the opponent goes.
This is for sure a legit problem. You can't even start combos off of 22 or b1 in the corner because the sword will never hit, although I've never had a problem off 112. Well, to be fair it's sort of not that big of a problem because they have to be literally touching the corner and that doesn't happen
that often in a real match, but it's still pretty bullshit that the sword whiffs there.