How much is "vastly different"?
SMJB said:
Two planets, vastly different sizes, similar surface gravities.
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By "vastly different sizes" I mean that I want the differential to be as vast as possible while keeping the above in mind and the fact that I want the larger world to still be a terrestrial world with continents similar in size to Earth's (and more of them).
If a difference in ratio of radii of 2 (and thus a surface area ratio of 4) satisfies the “vastly different” requirement, this is pretty easy to imagine:
Start with two roughly Earth-like planets (let’s call them “UE” and “LE” for “usual” and “little” Earth), and have one undergo an impact with a Mar-like planet, but rather than an indirect impact like the one theorized to have resulted in the formation of the Moon, a direct, more destructive one. Have LE much closer to the Sun than usual, so that it’s lower density, mostly silicate bits, are blown away by the solar wind, resulting in mostly iron remnant that re-coalesces into a “core only” version (with enough silicates to form an Earth-like crust, so perhaps best to call a “mantle-less” version) of UE, with about
1/3rd the mass and 1/2 the radius and 8/9ths (1/3 / (1/2)^3) the surface gravity.
The precise calculations for all this are tricky, because they must account for differences in pressure and temperature between LE and UE. The room temperature and pressure density of iron and nickel are 7.87 and 8.91 g/cm^3, the usual core 95/5% mixture, 7.93, but the density of UE’s core varies from about 9.9 (1.25 times) at the outermost of its liquid outer part to 13.1 (1.65) in its solid inner part. Without the pressure caused by its missing outer parts, LE’s “naked core” will have a slightly greater radius and significantly lesser density. There’s no need to sweat the details (other than for fun :) ), though, since we can imagine the pre-giant collision LE as being just enough more massive than UE to compensate for this.
A tricky part in this imagination scenario is
how to get LE from the close-to-the-Sun orbit needed to blow away its silicates after its giant impact to a comfortable Earth-like one. A complicated scenario involving a “wandering” giant planet with a very eccentric orbit that “ejected” LE from its close orbit, then luckily circularized it comes to mind. Nothing like that is theorized to have happened in our solar system, and the likelihood of it by a plausible solar system formation model is, I’d WAG, very small, but there are a truly vast number of Sun-like solar systems in the universe, so “unlikely” isn’t a barrier to reasonable imagination.
Another tricky bit of imagining is
where to put the two Earths, UE and LE. To be comfortable – that is, to have liquid surface water and similar atmospheres, they’d need to be in about the same orbit, but planets these sizes in the similar orbits is nearly a dynamic impossibility. If their orbits were exactly the same, they could just be 180% opposite, but such exactitude is vastly unlikely. If their orbits are only similar, eventually they’ll interact, colliding, or changing their orbits into something Earth-Venus or Earth-Mars-like, making one world hotter, the other colder.
A UE/LE radius ratio of 2 isn’t “vast” enough – if, for example, your plot need a radius ratio of 10 (surface area ration of 100), is harder for me to imaging. Making LE’s core out of a much denser elements (gold and platinum, for example, have densities 19.282 and 21.46 g/cm^3, vs iron-nickel’s 7.93), while keeping UE’s the usual iron-nickel, for example, could get you a radius ratio of about 5 (surface area 25 times). To get a radius ratio greater than 5, using this kind of scenario, some implausibly exotic material would be needed.
I think it’s a good idea to reconsider one of your story-building assumptions, SMJB:
By "similar surface gravity" I mean that someone from the smaller world could move to the heavier world with a minimum of health risks
Assuming the person in question is healthy and genetically earthling-like, I don’t think moving from a lower gravity world, such as the Moon, to one like Earth, would much of a long term-health risk. An adjustment period would be needed, similar to what one needs when recovering from a period of long-inactivity, such as severe multiple fractures or a long coma, but a body evolved to living in 1 g acceleration should eventually be OK in it, regardless of personal history. We don’t at present know with certainty, but I strongly expect that an ordinary human wouldn’t have health problems living for a long time with accelerations as low as 0.1 g. So, as far as gravity goes, your LE and UE could simply as like the Moon and Earth.
More critical than its direct health impact on people, for both worlds to have earthling-friendly environments,
gravity on LE and UE must retain a breathable atmosphere. They don’t have to be especially close to one another in pressure - about 0.07 times Earth’s is enough to keep body fluids from boiling, while pressures of up to about 50 times are livable if it doesn’t have too many gasses toxic at that pressure (such as nitrogen). Staying in this range isn’t easy, though, as the 2 most-Earth-like planets in or solar system show. Mars, at 0.107 Earth’s mass, and 0.378 its gravity, has only 0.006 ATMs pressure. Venus, 0.815 Earth mass 0.908, has 92 ATMs.
The great explaining trick in having 2 much different size earthling-friendly worlds isn’t, I think, having comfortable surface gravities, but having breathable atmospheres.