*Ideally* volume should be set at unity gain (generally this is 100%) and have the last piece of hardware at the end of the chain (generally the amp) control volume.
If you set higher than unity gain, you may experience clipping.
If you set lower than unity gain, then there is some digital software volume control is at work which will make you lose resolution. How important this is and whether you can hear it depends on your rig. But it's usually very subtle or unnoticeable unless you have really high end gear and exceptional hearing.
On a side note, I have a Creative X-Mod and I notice effects such as x-fi crystalizer and cmss often push volumes high enough to cause serious clipping at 100% volume. You may be expriencing clipping due to dsp effects on your sound blaster too.
Edited by MadCow - 10/21/10 at 1:40am