This aluminum lugs are rated for 2:0 copper wire, meaning they should be able to handle 283A: https://www.gordonelectricsupply.co...eai-iIXQ9HJunhhZE-nywJ1UL2uqESUwaAi5VEALw_wcB
So what do you think about the idea of using a long aluminum bolt with nut,etc to lock the bolt with lug attached into the terminal with Loctite or JB Weld and then torque the lug down into the terminal surface with the nut?
The nut can be loosened if the angle of the lug needs to be adjusted but otherwise, short sections of 2/0 thick-stranded copper wire (not thin stranded welders wire) is used to form connections between cells by positioning in a pair of lugs and tightening down the set screws.
Is this a good solution to avoid galvanic corrosion and preserve the soft aluminum threads in the terminals by only using them once (and never unthreading them)?
The only dissimilar metal is the copper stranded wire in the aluminum lug, but I’ve got that combo used throughout my electrical panels...
The problem with those thingsis that you'll apply some torque to the lug screw which might make it move on the terminal. I'd recommend to use flat aluminium stock like we do with copper.
If you're worried about the rigidity of such busbars then apply the same techniques than with copper: stack multiple thin busbars with a bridge form (I think it's CALB who does the copper version of that if you need examples)