A vehicle traction battery assembly including a battery cell, a busbar, and a thermal spray is provided. The battery cell may include a terminal having an angled taper upper portion extending therefrom. The busbar may define a through-hole having a taper defining an angle substantially opposite of the angled taper upper portion such that a cavity is defined therebetween when the terminal extends through the through-hole. The thermal spray may be deposited within the cavity to secure the busbar to the terminal. The thermal spray may be formed from a metallic powder selected to include particles that deform and connect when accelerated to a speed of approximately 500 mph or more to join the particles and form a bond securing the terminal to the busbar. The particles of the metallic powder may be iron, copper, aluminum, nickel, iron, or magnesium.