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Ah, yes, I see...if the joint doesn't conduct well, the solder will melt out "in a flash". :-)

The terminal clamps cold. The solder would fill the gaps and restore most of the contact area. Can't see calling it cosmetic only. The post and clamp could be preheated. Solder melts at ~half the temp of lead = safer.

More of the same issue : http://www.steelsoldiers.com/showthread.php?96420-Melted-Battery-Terminal-any-Options-And-new-Seat-Covers/page2 How about cleaning the post and clamp and melting solder down in the connection to fill the void? Much less dangerous (cooler) than lead.