In response to escalating global environmental concerns and the need for sustainable waste management, this study explores the transformative potential of high-temperature sintering in converting sludge incineration residues (SIR) into lightweight aggregates. The research investigates the influence of sintering temperature and time on the physical, mechanical, and environmental characteristics of the resulting aggregates. High-strength lightweight aggregates with optimal properties are achieved at 1085 ℃ and 10 minutes, exhibiting favorable freeze-thaw resistance. Microscopic analyses reveal the presence of glassy substances in the aggregates, with higher sintering temperatures leading to increased glassy content but also more substantial pores. Importantly, high-temperature sintering significantly reduces the leaching rate of heavy metal ions. This study contributes valuable insights into the micro-characteristics and environmental safety of SIR-sintered lightweight aggregates, providing a sustainable solution for waste utilization in the development of high-performance construction materials.