well many things happen and it is in a secrect file that no one can know
If you overstayed less than 6 month you will be banned to entering the US for 3 Years, and if you overstayed more than 6 Month you will be banned for 10 Years (AG)
If you are married to a US citizen but your tourist visa is expired and you lost your I-94, you should immediately apply for a new visa or return to your country. Your I-94 is filed electronically, and you can get a new copy from the Department of Homeland Security. If you don't take action yourself, you may end up being deported and not allowed to return.
file a petition for him
no depends were they came from
A US tourist visa is needed to visit the US as a tourist. If merely changing planes in Japan, a Japanese visa is not required.
No.
You can, but, you may get deported if your not legal to be in the States.
No. You need to apply for a separate US Visa.
Yes, unless you are already a US citizen you will need an immigrant visa that permits you to work, not a tourist visa.
No. You have to return to your country of origin.
US citizens don't need visas to enter the US, so it doesn't matter what kind of Indian visa you have. The Indian visa is permission to enter India.
You don't.