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It's not a DPI issue. Everything was the same size after upgrade. The issue fixed simply by reselecting the UI main font. Very strange.
Even with earlier QT, with some applications such as Viber, sometimes on the launcher I needed
/usr/bin/env QT_AUTO_SCREEN_SCALE_FACTOR=0 QT_SCALE_FACTOR=1.20
(or some other scale).
It seemed to be random per laptop with 1920 x 1080 screens even of the same size.
My 3840 x 2160 screen is 28" and the laptop 1920 x 1080 is 15", both 16:9. My older 4:3 screen laptop from 2002 was a little more than 15" but 1600 x 1200 which is better than 1920 x 1080 for PDFs.
So those are all similar DPI settings. It's only so called "Retina" screens (i.e. 10" @ 2K or 15" @ 4K etc) that need a HiDPI setting and ANY software setting it automatically should not unless opted in and the SW can read the screen physical size from somewhere. Actual X and Y dots without the screen physical size is meaningless.
Actually it's stupid on Win7 & Win10 you can't go LESS than 100%. On a screen that's only 720, 768 or 800 high you might want to set the DPI to 72, i.e. shrink all the fonts and controls, no matter what the real DPI is so that windows fit. A lot of stuff assumes a minimum of 1024 lines for display panel.
XP can go from 20% to 500% on GUI scaling, but not all windows and controls scale. Vista/Win7/Win8/Win10/Win11 can't be used on lower resolution screens, no matter the DPI because they don't go less than 100%.
So called HiDPI mode is 400% windows scale. Apple uses 2 x 2 per pixel in hiDPI mode, so you are in trouble with a 24" or 28" and larger 4K display if Apple doesn't use the size of it
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