Systems and methods for fabricating objects including amorphous metal using techniques akin to additive manufacturing

A method of making a structural amorphous metal coating, the method comprising:

• applying, in an inert gas or vacuum environment, a first layer of molten metallic alloy to a surface of an object using a spraying technique and a spot size having a diameter of about 1 to 100 mm, wherein the spraying technique employs a molten form of a metallic alloy as a spray feedstock, wherein the metallic alloy comprises at least 50 atomic % of Ti, Zr, Hf, Cu, or any combination of these;
• cooling the first layer of molten metallic alloy such that it solidifies and thereby forms a first cooled and solidified layer comprising amorphous metal conformal with the surface, wherein the amorphous metal comprises at least 50 atomic % of Ti, Zr, Hf, Cu, or any combination of these;
• applying, in the inert gas or vacuum environment, a second layer of the molten metallic alloy onto the first cooled and solidified layer comprising the amorphous metal using the spraying technique and the spot size having a diameter of about 1 to 100 mm;
• and
• cooling the second layer of the molten metallic alloy such that it solidifies and thereby forms a second cooled and solidified layer comprising the amorphous metal on the first cooled and solidified layer comprising the amorphous metal;
• wherein a coating of the amorphous metal on the object comprises an aggregate of the cooled and solidified layers comprising the amorphous metal, the coating comprising at least 50 atomic % of Ti, Zr, Hf, Cu, or any combination of these.