Pellet substrates for vaporizing and delivering an aerosol

Pellet substrates configured for use with a vapor delivery device to vaporize and deliver an aerosol to a user include porous, substantially inert activated carbon and activated alumina pellets that have generally spherical, semi-spherical and/or rounded shapes. The pellet substrates are formed by mixing the pellets together with a liquid solution of an aerosol former admixed with flavoring and/or nicotine, tobacco powder, or tobacco extract such that the liquid solution is absorbed into and/or adsorbed onto the porous structure of the pellets with or without the addition of heat. The pellets may be coated with an inert dry powder, such as calcium carbonate, to better adhere the liquid solution to the porous surfaces of the pellets. Alternatively, or in addition, the pellets may be coated with a liquid solution of a cellulose gum, such as sodium carboxymethylcellulose, and distilled water to reduce fracturing, cracking, chipping and dusting of the pellet substrates.