I want to get engaged to my girlfriend who is here on a f-1 visa. If she moves in with me will she still need a sponsor?

You must be married before you can file for her if she is in the US. After marriage, you can apply for her residency and work permit.

(Canadian citizen) can you go to the immigration interview (Montreal) without physical. Physical scheduled after.

You cannot be approved without the physical. They may turn you around without it since that was a requirement prior to the interview.

There is no prohibition against putting two packages in the same envelope but keep in mind they are two separate cases.

How do I file a motion to re-open a criminal case that went to trial and that I was found guilty in the state of Texas?

Not possible. You need post conviction relief.

I am a imigrant dat cam to the us at the age of 5 and lived all my life here now I am in 10th grade how can I get a green card?

Tough situation. You and your family should seek legal advice.

Can I still withdraw a I-130 petition initially denied by an immigration officer and subject for appeal to BOA's final decision?

Yes...

Expungement/Immigration

expungment either way is fine but it does not help your immigration case.

Possible, she may need a j-1 waiver.

Will immigration judge make decision at our individual hearing?

The judge can consider anything but without knowing the judge, hard to say what he/she will consider.

What next?

Its hard to say without having all the facts.