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Hi, complete newbie to this forum, however I am not a newbie to replacement iPhones. From 3G to 4 I have had 14 replacements, 5 of these being iPhone 4's.

I'm from the UK, so the rules around replacements may be a little different here, but here is my suggestion which may help you get a BRAND NEW replacement (sealed retail box with a full 1 yr warranty) iPhone rather than those crappy 5K s/n refurbs

Ask for a CRU replacement iPhone at the genius bar, tell them to look at your case history and ask to speak to the manager about your problems with refurbs. As you have had so many I would be surprised if they dont offer you a CRU :)
 
Had a good run with my 6th iPhone 4. The power button for this one is stuck too. Apple care ran out. Never paying premium for apple care and unlocked phone again. Paid close to $1000 after tax for a 32gb iPhone 4 unlocked plus $75 apple care is not worth it.
 
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